Football helmet with components additively manufactured to manage impact forces

ABSTRACT

The invention relates to a multi-step method with a number of processes and sub-processes that interact to allow for the selection, design and/or manufacture of a protective sports helmet for a specific player, or a recreational sports helmet for a specific person wearing the helmet. Once the desired protective sports helmet or recreational sports helmet is selected, information is collected from the individual player or wearer regarding the shape of his/her head and information about the impacts he/she has received while participating in the sport or activity. The collected information is processed to develop a bespoke energy attenuation assembly for use in the protective helmet. The energy attenuation assembly includes at least one energy attenuation member with a unique structural makeup and/or chemical composition. The energy attenuation assembly is purposely engineered to improve comfort and fit, as well as how the helmet responds when an impact or series of impacts are received by the helmet.

CROSS-REFERENCE TO OTHER APPLICATIONS

U.S. Provisional Patent Application Ser. No. 62/770,453, entitled“Football Helmet With Components Additively Manufactured To Optimize TheManagement Of Energy From Impact Forces,” filed on Nov. 21, 2018, thedisclosure of which is hereby incorporated by reference in its entiretyfor all purposes.

U.S. Design patent application Ser. No. 29/671,111, entitled “InternalPadding Assembly of a Protective Sports Helmet,” filed on Nov. 22, 2018,the disclosure of which is hereby incorporated by reference in itsentirety for all purposes.

U.S. patent application Ser. No. 16/543,371 entitled “System And MethodFor Designing And Manufacturing A Protective Helmet Tailored To ASelected Group Of Helmet Wearers,” filed on Aug. 16, 2019 and U.S.Provisional Patent Application Ser. No. 62/719,130 entitled “System andMethods for Designing and Manufacturing a Protective Sports Helmet Basedon Statistical Analysis of Player Head Shapes,” filed on Aug. 16, 2018,the disclosure of these are hereby incorporated by reference in theirentirety for all purposes.

U.S. Provisional Patent Application Ser. No. 62/778,559, entitled“Systems And Methods For Providing Training Opportunities Based On DataCollected From Monitoring A Physiological Parameter Of Persons EngagedIn Physical Activity,” filed on Dec. 12, 2018, the disclosure of whichis hereby incorporated by reference in its entirety for all purposes.

U.S. patent application Ser. No. 15/655,490 entitled “System And MethodsFor Designing And Manufacturing A Bespoke Protective Sports Helmet,”filed on Jul. 20, 2017 and U.S. Provisional Patent Application Ser. No.62/364,629 entitled “System And Methods For Designing And ManufacturingA Bespoke Protective Sports Helmet That Provides Improved Comfort AndFit To The Player Wearing The Helmet,” filed on Jul. 20, 2016, thedisclosure of these are hereby incorporated by reference in theirentirety for all purposes.

U.S. Pat. No. 10,159,296 entitled “System and Method for Custom Forminga Protective Helmet for a Customers Head,” filed on Jan. 15, 2014, U.S.Provisional Patent Application Ser. No. 61/754,469 entitled “System andmethod for custom forming sports equipment for a user's body part,”filed Jan. 18, 2013, U.S. Provisional Patent Application Ser. No.61/812,666 entitled “System and Method for Custom Forming a ProtectiveHelmet for a User's Head,” filed Apr. 16, 2013, U.S. Provisional PatentApplication Ser. No. 61/875,603 entitled “Method and System for Creatinga Consistent Test Line within Current Standards with Variable CustomHeadforms,” filed Sep. 9, 2013, and U.S. Provisional Patent ApplicationSer. No. 61/883,087 entitled “System and Method for Custom Forming aProtective Helmet for a Wearer's Head,” filed Sep. 26, 2013, thedisclosure of these are hereby incorporated by reference in theirentirety for all purposes.

U.S. Pat. No. 9,314,063 entitled “Football Helmet with ImpactAttenuation System,” filed on Feb. 12, 2014 and U.S. Provisional PatentApplication Ser. No. 61/763,802 entitled “Protective Sports Helmet withEngineered Energy Dispersion System,” filed on Feb. 12, 2013, thedisclosure of these are hereby incorporated by reference in its entiretyfor all purposes.

U.S. Design Pat. D850,011 entitled “Internal Padding Assembly of AProtective Sports Helmet,” filed on Jul. 20, 2017, U.S. Design Pat.D850,012 entitled “Internal Padding Assembly of A Protective SportsHelmet,” filed on Jul. 20, 2017, and U.S. Design Pat. D850,013 entitled“Internal Padding Assembly of A Protective Sports Helmet,” filed on Jul.20, 2017, the disclosure of these are hereby incorporated by referencein their entirety for all purposes.

U.S. Design Pat. D603,099 entitled “Sports Helmet,” filed on Oct. 8,2008, U.S. Design Pat. D764,716 entitled “Football Helmet,” filed onFeb. 12, 2014, and U.S. Pat. No. 9,289,024 entitled “Protective SportsHelmet,” filed on May 2, 2011, the disclosure of these are herebyincorporated by reference in their entirety for all purposes.

TECHNICAL FIELD

The invention relates to a protective sports helmet purposely engineeredto improve comfort and fit, as well as how the helmet responds when animpact or series of impacts are received by the helmet when worn by aplayer. Specifically, this invention relates to a football helmet, whereat least one energy attenuation component is specifically designed andmanufactured using an additive manufacturing process to adjust how thehelmet fits and responds to impact forces received by the helmet when itis worn by a player.

BACKGROUND OF THE INVENTION

Protective sports helmets, including those worn during the play of acontact sports, such as football, hockey, and lacrosse, typicallyinclude an outer shell, an internal pad assembly coupled to an interiorsurface of the shell, a faceguard or face mask, and a chin protector orstrap that releasably secures the helmet on the wearer's head. However,most traditional helmets do not use advanced techniques to create ahelmet that is specifically designed to respond in a certain manner whenan impact or series of impacts are received by the helmet. Additionally,most traditional helmets do not contain components that are specificallyselected or tailored to a particular player's playing level, position,medical history and/or to at least one of the player's anatomicalfeatures.

Accordingly, there is an unmet need for a helmet that uses advancedstructures (e.g., lattice cell types), advanced materials with tailoredchemical compositions (e.g., specific light sensitive polymers), andadvanced helmet design/manufacturing techniques (e.g., finite elementanalysis, neural networks, additive manufacturing) to create a helmetthat is specifically tailored to a particular player's playing level,position, medical history and/or to at least one of the player'sanatomical features (such as the player's head topography).Additionally, there is also an unmet need to create a helmet thatcontains components that are specifically tailored to a particularplayer's playing level, position, and/or to at least one of the player'sanatomical features (such as the player's head topography).

The description provided in the background section should not be assumedto be prior art merely because it is mentioned in or associated with thebackground section. The background section may include information thatdescribes one or more aspects of the subject of technology.

SUMMARY OF THE INVENTION

This disclosure generally provides a multi-step method with a number ofprocesses and sub-processes that interact to allow for the selection,design and/or manufacture of (i) a protective contact sports helmet fora specific player, or (ii) a protective recreational sports helmet for aspecific person wearing the helmet.

In the context of a protective contact sports helmet, the inventivemulti-step method starts with the selection of a desired sports helmetand then collecting information from the individual player. In thecontext of a protective recreational sports helmet, the inventivemulti-step method starts with the selection of a desired recreationalsports helmet and then collecting information from the individualwearer. This collection of information may include information about theshape of a player's head and information about the impacts the playerhas received while participating in the sport or activity. Once thisinformation is collected, it can be used to: (i) recommend a stockhelmet or stock helmet component that best matches the player's orwearer's collected and processed information or (ii) develop a bespokeenergy attenuation assembly for use in the contact sports helmet or therecreational sports helmet based on the player's or wearer's collectedand processed information, respectively.

The contact sports helmet and the recreational sports helmet eachinclude an energy attenuation assembly with one or more bespoke energyattenuation members, where the energy attenuation member includes aregion with a structural makeup and/or chemical composition that isdifferent from other regions of that same member. Alternatively, theenergy attenuation assembly includes a first member with a firststructural makeup and/or chemical composition that differs from a secondstructural makeup and/or chemical composition of a second member of theattenuation assembly. The energy attenuation assembly could include afirst member with a first region with a structural makeup and/orchemical composition that is different from a second region of the firstmember, and a second member with a first region with a structural makeupand/or chemical composition that is different from a second region ofthe second member and the first and second regions of the first member.

To efficiently create members of the energy attenuation assembly havingdiffering structural makeups and/or chemical compositions, thedevelopment process involves the usage of advanced structures (e.g.,lattice cell types), advanced materials with tailored chemicalcompositions (e.g., specific light sensitive polymers), and advancedhelmet design/manufacturing techniques (e.g., finite element analysis,neural networks, additive manufacturing) are utilized while accountingfor the player's specific playing level, position, medical historyand/or to at least one of the player's anatomical features. The energyattenuation assembly is positioned within an outer shell of theprotective contact sports helmet or the protective recreational sportshelmet. When the contact sports helmet is configured for use whileplaying American football, hockey or lacrosse, the helmet includes aface guard or facemask and a chin strap.

It is understood that other configurations of the subject technologywill become readily apparent to those skilled in the art from thefollowing detailed description, wherein various configurations of thesubject technology are shown and described by way of illustration. Aswill be realized, the subject technology is capable of other anddifferent configurations, and its several details are capable ofmodification in various other respects, all without departing from thescope of the subject technology. Accordingly, the drawings and detaileddescription are to be regarded as illustrative in nature and not asrestrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawing figures depict one or more implementations in accord withthe present teachings, by way of example only, not by way of limitation.In the figures, like reference numerals, refer to the same or similarelements.

FIG. 1 is a flow chart showing a method of selecting, designing andmanufacturing a protective sports helmet that includes additivelymanufactured components;

FIG. 2 is a flow chart showing a process of selecting a protectivesports helmet;

FIGS. 3A-3B are flow charts showing a process for collecting playerimpact information;

FIG. 4 is a schematic view of an exemplary system that utilizes theprocess shown in FIGS. 3A-3B to collect and store player impactinformation;

FIG. 5 is a schematic view of an exemplary impact sensing device that isconfigured to be placed within a protective sports equipment, such asthe helmet of FIG. 4;

FIG. 6A is a flow chart showing the process for collecting player shapeinformation;

FIG. 6B is a flow chart showing the optional process for collectingadditional player shape information using a scanning helmet;

FIG. 7 shows a first exemplary scanning apparatus that is configured tocollect player shape information, wherein said apparatus is showncollecting shape information from a player's head that is partiallycovered with a scanning hood;

FIG. 8 is an example of a pattern that may be placed on the scanninghood shown in FIG. 7;

FIG. 9 is a second exemplary scanning apparatus that is configured tocollect player shape information with an exemplary software applicationdisplayed on said scanning apparatus;

FIG. 10 is an electronic device displaying a graphical representation ofthe path that the first or second exemplary scanning apparatuses maytake during the process of obtaining player shape information;

FIG. 11 shows the first exemplary scanning apparatus, which iscollecting additional shape information by scanning a helmet worn on aplayer's head;

FIG. 12 is a flow chart showing a process for creating a player profile;

FIG. 13 is a schematic showing the electronic device displaying aplurality of player impact information sources and an exemplary playerimpact matrix;

FIG. 14 shows the electronic device displaying a plurality of playershape information sources;

FIG. 15 shows the electronic device displaying multiple views of athree-dimensional (3D) body part model, namely of the player's headregion, created from the player shape information, which has a number ofanthropometric points positioned thereon;

FIGS. 16A-16C shows the electronic device displaying a 3D head modelcreated from the shape information, wherein the 3D head models include afitting surface of the head model;

FIG. 17 shows a process of selecting stock helmets or stock helmetcomponents;

FIG. 18 is a schematic showing the electronic device displaying a fourexemplary complete stock helmet models and information that isassociated with the complete stock helmet models, which includes shapeinformation and impact information;

FIG. 19 is a schematic showing the electronic device displaying fourexemplary 3D head shapes in cross-section that are associated with thecomplete stock helmet models shown in FIG. 18;

FIG. 20 is a schematic showing the electronic device displaying across-sectional view of an exemplary 3D complete stock helmet modelalong 1-1 line in FIG. 20;

FIGS. 21-23 show processes for recommending a complete stock helmetmodel based upon the player's profile and player's prior helmetselections;

FIG. 24 is a schematic showing the electronic device displaying agraphical rendering of the player's head model and a modified surface ofthe player's head model in cross-section;

FIG. 25 is a schematic showing the electronic device graphicallyportraying a cross-sectional image of the player's head model against asize large complete stock helmet model;

FIG. 26 is a schematic showing the electronic device graphicallyportraying a cross-sectional image of the player's head model against asize small complete stock helmet model;

FIG. 27 is a schematic showing the electronic device graphicallyportraying a cross-sectional image of the player's head model against asize medium complete stock helmet model;

FIG. 28 shows a process for selecting a stock helmet component;

FIG. 29 shows a process for generating a custom shaped helmet model;

FIG. 30 is a schematic showing the electronic device graphicallyportraying a cross-sectional image of the player's head model against acomplete stock helmet model;

FIG. 31 is a schematic showing the electronic device graphicallyportraying a cross-sectional image of the player's head model and acustom shaped energy attenuation assembly;

FIG. 32 shows a process for generating a custom shaped helmet model;

FIG. 33 shows a transition from a model of an energy attenuation member(created in FIG. 32) to a 3D printed bespoke energy attenuation member;

FIGS. 34A-34B are flow charts showing a process of generating optimizedhelmet prototype models using a response surface methodology;

FIG. 35 is a schematic showing the electronic device displaying a chartof the independent variables of the optimization process;

FIG. 36 is a schematic showing the electronic device displayingexemplary 3D graphs created using the processes described in FIGS.34A-34B and a graph created from overlaying each of thesethree-dimensional graphs on top of one another;

FIG. 37 is a flow chart showing a process of generating optimized helmetprototype models using a brute force methodology;

FIG. 38 is a flow chart showing a process of generating optimized helmetprototype models using a hybrid methodology;

FIG. 39 is a flow chart showing a process of generating energyattenuation member models using a lattice engine;

FIG. 40 is a schematic showing the electronic device displaying sevenexemplary energy attenuation member models;

FIG. 41 is a schematic showing the electronic device displayingexemplary digital testing of an energy attenuation member model, whereinthe energy attenuation member model has been partitioned into varioussegments based on digital testing;

FIG. 42 is a schematic showing the electronic device displaying sixexemplary energy attenuation member models, which show partitionedsegments that extend across the energy attenuation member;

FIG. 43 is a schematic showing the electronic device displaying sixexemplary energy attenuation member models, which show the partitionedsegments that extend through the energy attenuation member;

FIG. 44 is a flow chart showing a process of generating player specifichelmet model;

FIGS. 45A-45B are schematics showing the electronic device displayingthe assembled energy attenuation member models;

FIG. 46 shows the electronic device displaying the testing of thecomplete stock helmet models;

FIG. 47 is a flow chart showing a process of manufacturing a CS, CP, orCS+CP helmet models;

FIG. 48 is a schematic showing the electronic device displaying thepreparation of the energy attenuation member models for manufacturing;

FIGS. 49A-49C show the manufacturing of the energy attenuation members;

FIG. 50A shows a perspective view of a protective sports helmet that iscapable of receiving stock energy attenuation members or custom energyattenuation members;

FIG. 50B is a perspective view of the helmet of FIG. 50A, wherein theenergy attenuation assembly includes custom energy attenuation members;

FIG. 51A shows a side view of a protective sports helmet that is capableof receiving stock energy attenuation members or custom energyattenuation members;

FIG. 51B is a side view of the helmet of FIG. 51A, wherein the energyattenuation assembly includes custom energy attenuation members;

FIG. 52A shows a top view of a protective sports helmet that is capableof receiving stock energy attenuation members or custom energyattenuation members;

FIG. 52B is a top view of the helmet of FIG. 52A, wherein the energyattenuation assembly includes custom energy attenuation members;

FIG. 53A shows a rear view of a protective sports helmet that is capableof receiving stock energy attenuation members or custom energyattenuation members;

FIG. 53B is a rear view of the helmet of FIG. 53A, wherein the energyattenuation assembly includes custom energy attenuation members;

FIG. 54A shows a bottom view of a protective sports helmet that iscapable of receiving stock energy attenuation members or custom energyattenuation members;

FIG. 54B is a bottom view of the helmet of FIG. 54A, wherein the energyattenuation assembly includes custom energy attenuation members;

FIGS. 55A-55E are various views of a stock energy attenuation assemblysuitable for installation within a protective sports helmet;

FIGS. 56A-B are various views of a stock front energy attenuation memberof the energy attenuation assembly shown in FIGS. 55A-55E;

FIGS. 57A-B are various views of the stock front energy attenuationmember of the energy attenuation assembly shown in FIGS. 55A-55E;

FIG. 57C is a cross-sectional view of the stock front energy attenuationmember taken along the 57-57 line shown in FIG. 57A;

FIGS. 58A-58B are compression curves associated with a first embodimentof the stock front energy attenuation member of the energy attenuationassembly shown in FIGS. 55A-55E;

FIGS. 59A-59C show different regions contained within a secondembodiment of the stock front energy attenuation member and compressioncurves that are associated with each of these regions;

FIGS. 60A-C are various views of a stock crown energy attenuation memberof the energy attenuation assembly shown in FIGS. 55A-55E;

FIGS. 61A-B are various views of stock left and right side energyattenuation members of the energy attenuation assembly shown in FIGS.55A-55E;

FIGS. 62A-62B are compression curves associated with the stock left andright side energy attenuation members of the energy attenuation assemblyshown in FIGS. 55A-55E;

FIGS. 63A-63B are various views of stock left and right jaw energyattenuation members of the energy attenuation assembly shown in FIGS.55A-55E;

FIGS. 64A-64B are various views of a stock rear energy attenuationmember of the energy attenuation assembly shown in FIGS. 55A-55E;

FIGS. 65A-65C are various views of a stock occipital energy attenuationmember of the energy attenuation assembly shown in FIGS. 55A-55E;

FIGS. 66A-66C are different regions contained within the stock occipitalenergy attenuation member and compression curves that are associatedwith each of these regions;

FIG. 67 is an exploded view of the custom energy attenuation assemblysuitable for installation within a protective sports helmet, showing thevarious attenuation members of the assembly;

FIGS. 68A-C are various views of a custom front energy attenuationmember of the energy attenuation assembly shown in FIG. 67;

FIGS. 69A-C are various views of a custom crown energy attenuationmember of the energy attenuation assembly shown in FIG. 67;

FIGS. 70A-B are various views of custom left and right side energyattenuation members of the energy attenuation assembly shown in FIG. 67;

FIGS. 71A-D are various views of custom left and right jaw energyattenuation members of the energy attenuation assembly shown in FIG. 67;

FIGS. 72A-B are various views of a custom rear energy attenuation memberof the energy attenuation assembly shown in FIG. 67;

FIG. 73 is a zoomed view of a region of a custom rear energy attenuationmember of the energy attenuation assembly shown in FIG. 72A;

FIGS. 74A-74C show a second embodiment of a custom rear energyattenuation member, which includes a first region and a second regionand compression curves associated with the first region; and

FIGS. 75A-75C show the second embodiment of a custom rear energyattenuation member, which includes a first region and a second regionand compression curves associated with the second region.

DETAILED DESCRIPTION

In the following detailed description, numerous specific details are setforth by way of examples in order to provide a thorough understanding ofthe relevant teachings. However, it should be apparent to those skilledin the art that the present teachings may be practiced without suchdetails. In other instances, well-known methods, procedures, components,and/or circuitry have been described at a relatively high-level, withoutdetail, in order to avoid unnecessarily obscuring aspects of the presentdisclosure.

While this disclosure includes a number of embodiments in many differentforms, there is shown in the drawings and will herein be described indetail particular embodiments with the understanding that the presentdisclosure is to be considered as an exemplification of the principlesof the disclosed methods and systems, and is not intended to limit thebroad aspects of the disclosed concepts to the embodiments illustrated.As will be realized, the disclosed methods and systems are capable ofother and different configurations and several details are capable ofbeing modified all without departing from the scope of the disclosedmethods and systems. For example, one or more of the followingembodiments, in part or whole, may be combined consistent with thedisclosed methods and systems. As such, one or more steps from the flowcharts or components in the Figures may be selectively omitted and/orcombined consistent with the disclosed methods and systems. Accordingly,the drawings, flow charts and detailed description are to be regarded asillustrative in nature, not restrictive or limiting.

A. Definitions

This section identifies a number of terms and definitions that are usedthroughout the Application. The term “player” is a person who wears theprotective sports helmet while engaged in practice or game play of thesport. The term “helmet wearer” or “wearer” is a player who is wearingthe helmet. The term “designer” is a person who designs, tests, ormanufactures the helmet.

A “protective sports helmet” is a type of protective equipment that aplayer or participant wears on his/her head while engaged in anactivity, such as the play of a sport or an activity.

A “protective contact sports helmet” or “contact sports helmet” is atype of protective sports helmet that the player wears while he/she isengaged in the play of the sport, such as American football, hockey orlacrosse, that typically requires a team of players. It is common forthe rules and the regulations of the particular contact sport to mandatethat the player wear the contact sports helmet while he/she is engagedin playing the sport. Contact sports helmets typically must comply withsafety regulations promulgated by a governing body, such as NOCSAE forfootball helmets.

A “protective recreational sports helmet” or “recreational sportshelmet” is a type of protective sports helmet that is worn by the wearerwhile he/she is participating in a recreational activity such ascycling, climbing sports, skiing, snowboarding, motorsports ormotorcycling, that typically can be done by an individual wearer.Recreational sports helmets typically must also comply with safetyregulations promulgated by a governing body, such as ASTM/ANSIregulations for cycling helmets and Department of Transport (DOT) formotorsports helmets and motorcycling helmets.

An “energy attenuation assembly” is an internal assembly of energyattenuating members that are designed to collectively interact to enablethe protective sports equipment, for example, the contact sports helmetor recreational sports helmet to attenuate energies, such as linearacceleration and/or rotational acceleration, from impacts received bythe sports helmet. As detailed below, the energy attenuation assemblycan include multiple attenuating members that are designed to optimizethe performance of the energy attenuation assembly for the helmet.

An “energy attenuation member(s)” is a component of the energyattenuation assembly that is installed within the helmet. The energyattenuation member is a three-dimensional (3D) component that has both avolume and an outer periphery. The volume and outer periphery aredefined by an X, Y and Z Cartesian coordinate system where the Zdirection is defined out of plane to provide the energy attenuationmember with a height or thickness. When the energy attenuation member ispart of an assembly installed within a contact sports helmet, theZ-direction thickness represents the dimension of the energy attenuationmember between the player's head and an inner surface of a shell of thesports helmet when the sports helmet is actually worn on the player'shead.

The term “member region” is a zone or volume of an energy attenuationmember, where the member region has properties, including (i) latticecells, (ii) lattice densities, (iii) lattice angles, (iv) mechanicalproperties and/or (v) chemical properties. A single energy attenuationmember can include one or more member regions, where region A has afirst set of properties (i)-(v) and region B has a second set ofproperties (i)-(v) that differ. It should be understood that if there ismore than a minor variation in the properties (i)-(v), then there aretwo distinct member regions. For example, if there are differences inthe lattice cell's geometry, then those lattice cells identify twodistinct member regions.

The term “lattice cell” is the simplest repeating unit contained withina member region of an energy attenuation member. The lattice cell has ageometry that is due to the type of cell unit. It should be understoodthat various types of lattice cell units are contemplated by thisdisclosure, some of which are shown in FIG. 39. In that Figure, some ofthe lattice cell types are comprised of a number of lattice “struts”which are elongated structures that intersect with one another to formthe specific geometry of the lattice cell. Depending upon designparameters, the thicknesses and/or length of the lattice struts can bealtered in a particular lattice cell. However, that alteration shouldnot change the designation of the lattice cell (e.g., increasing thestrut thickness of a strut-based lattice should not change itsdesignation). It should further be understood that minor variations inthe geometry of the lattice cells due to the manufacturing process ortolerances do not result in a new categorization of the lattice cell.

The term “lattice density” is the density of a particular lattice cell.The lattice density can vary based upon a number of design parameters,including but not limited to the configuration of the struts that formthe lattice cell. It should be understood that minor variations in thelattice densities due to the manufacturing process or tolerancesmanufacturing process or tolerances do not result in a newcategorization of the lattice density.

The term “lattice angle” is the angle at which a lattice cell ispositioned normal to a reference surface of the member. It should beunderstood that minor variations in the lattice angles due to themanufacturing process or tolerances manufacturing process or tolerancesdo not result in a new categorization of the lattice angle(s).

The term “anatomical features” can include any one or any combination ofthe following: (i) dimensions, (ii) topography and/or (iii) contours ofthe player's body part including, but not limited to, the player'sskull, facial region, eye region and jaw region. Because the disclosedhelmet is worn on the player's head and the energy attenuation assemblymakes contact with the player's hair, the “anatomical features” termalso includes the type, amount and volume of the player's hair or lackthereof. For example, some players have long hair, while other playershave no hair (i.e., are bald). While the present disclosure, as will bediscussed in detail below, is capable of being applied to any body partof an individual, it has particular application the human head.Therefore, any reference to a body part is understood to encompass thehead, and any reference to the head alone is intended to includeapplicability to any body part. For ease of discussion and illustration,discussion of the prior art and the present disclosure is directed tothe human head, by way of example, and is not intended to limit thescope of discussion to the human head.

The term “custom shaped energy attenuation assembly model” or “CS model”is a digital or computerized model of the energy attenuation assemblythat has been altered based upon information gathered and processed fromthe player's profile 220.99 (see below) that includes a head model.

The term “custom performance energy attenuation assembly model” or “CPmodel” is a digital or computerized model of the energy attenuationassembly that has been altered based upon information gathered andprocessed from the player's profile 320.99 (see below) that includes animpact matrix.

The term “custom performance and custom shaped energy attenuationassembly model” or “CP+CS model” is a digital or computerized model ofthe energy attenuation assembly that has been altered or created basedupon information gathered and processed from the player's profile 120.99(see below) that includes both a head model and an impact matrix.

The term “player specific helmet model” is a digital or computerizedmodel of a protective sports helmet that is derived from one of theCP+CS model, CP model, or CS model. In contrast to the CP+CS model, CPmodel, and CS model that is not designed to be manufactured, the playerspecific helmet model is designed to be manufactured to create a helmetto be worn by the player or wearer.

The term “complete stock helmet model” is a digital or computerizedmodel of the protective sports helmet that has been designed anddeveloped in connection with U.S. patent application Ser. No.16/543,371. Specifically, in U.S. patent application Ser. No. 16/543,371the complete stock helmet model was referred to as the “complete helmetmodel.”

The term “stock helmet(s)” is a helmet that is pre-manufactured anddesigned for a select “player group” from amongst a larger population ofhelmet wearers. The stock helmet is not specifically designed or bespokefor one player or wearer. Stock helmets provide a number of benefits tothe helmet manufacturer, including but not limited to improvedefficiencies in manufacturing, raw material usage and inventorymanagement.

The term “player group” is a group or subset of players or wearers thatare part of a larger population of players or wearers who participate inthe sporting activity. In the context of contact sports helmets, theplayer group is a subset of players wearing helmets from amongst thebroader group of players wearing helmets during the play of the contactsport.

The term “stock helmet components” are pre-manufactured components forprotective sports helmets that are not specifically designed for oneplayer or wearer, but instead are designed for a select player groupfrom amongst a larger population of players or wearers.

The term “player specific helmet” is a bespoke protective sports helmet,with an energy attenuation assembly, that is purposely designed,configured and manufactured to match the player or wearer'scharacteristics, including his/her: (i) anatomical features of the head,(ii) impact history, or (iii) both the anatomical features of the headand impact history.

The term “player specific helmet” is a bespoke protective sports helmet,with an energy attenuation assembly, that is purposely designed,configured and manufactured to match the player or wearer'scharacteristics, including his/her: (i) anatomical features of the head,(ii) impact history, or (iii) both the anatomical features of the headand impact history.

B. Selection of a Protective Sports Helmet

A multi-step method 1 including a number of processes and sub-processesthat interact to allow for the selection, design and/or manufacture of(i) a protective contact sports helmet for a specific player, or (ii) aprotective recreational sports helmet for a specific person wearing thehelmet. The multi-step method 1 begins with the player selecting aprotective sports helmet from a plurality of protective sports helmetsusing an internet enabled device in step 50. The information associatedwith the selected protective sports helmet: (i) is used to determinewhat information or data is needed from the player and (ii) will informvarious parameters of the helmet, including but not limited to, thetopography of an interior surface of the energy attenuation assembly,how the energy attenuation assembly is manufactured, or the structuraland/or chemical composition of the energy attenuation assembly. It isunderstood that if the method 1 includes a step or process that isirrelevant to the selection, design and/or manufacture of the contactsports helmet or the recreational sports helmet, then that step orprocess can be omitted without negatively impacting the functionality ofthe method 1.

As shown in FIG. 2, this process is started 50.1 by an operator orplayer opening up a software application or browser to select orconfigure a protective sports helmet. If the operator or player does nothave the software application downloaded on their device, they candownload it from an internet database (e.g., iTunes, Google Play, oretc.). Alternatively, the operator or player may go to the protectivesports helmet configurator URL using an internet enabled device (e.g., acomputer or cellphone). Upon opening the protective sports helmetconfigurator, the operator may be requested to input information aboutthe player (e.g., player's name, age, playing level, position, and/orinjury history). Once this information is entered into the system, theplayer P can have the system find a previously created profile thatincludes information that is associated with the player or the playercan create a new profile. After the player's profile is populated withthe available information, the protective sports helmet configuratorprompts the operator or player P to select the desired protective sportshelmet from a plurality of protective sports helmets. It should beunderstood that additional information may be added to the playerprofile during the process of selecting a protective sports helmet, suchas shape information from a scan of the player.

Next, the protective sports helmet configurator allows the operator orplayer to select: (i) a new energy attenuation assembly 2000, 3000 for apreviously acquired helmet by selecting 50.10 or (ii) a new helmet 1000by selecting 50.50. If the operator or player selects the new energyattenuation assembly 2000, 3000 for a previously acquired helmet byselecting 50.10, the operator or player will be required to certify thecondition of the previously acquired helmet 50.12. This may be done byrequiring the operator or player to input the model of the helmet, inputthe year the helmet was bought, upload pictures of the helmet, includingall labels, and/or attest to the condition of the helmet. If theprotective sports helmet configurator determines that the helmet is notin an acceptable condition, then the protective sports helmetconfigurator may suggest to the operator or player that they purchase anew helmet 50.14.

If the protective sports helmet configurator determines that the helmetis in an acceptable condition and is capable of receiving a new energyattenuation assembly 2000, 3000 in step 50.16, then the protectivesports helmet configurator allows the operator or player to select thetopography or shape of the inner surface of the energy attenuationassembly 2000, 3000. In particular, the player may select: (i) a stockshaped energy attenuation assembly 2000 by selecting 50.18 or (ii) acustom shaped energy attenuation assembly 3000 by selecting 50.22. Ifthe operator or player picks the stock shaped energy attenuationassembly 2000 by selecting 50.18, then the system will ask the user toinput/acquire/collect shape information about the player's body part andspecifically the player's head region. This shape information will beutilized by the system in the following steps to suggest the stockenergy attenuation assembly 2000 that will best fit the player's head.Next, the operator or player may select how the energy attenuationassembly 2000 is manufactured. For example, the operator or player mayselect: (i) a standard method of manufacturing the energy attenuationassembly, including foam molding, by selecting 50.20 or (ii) astate-of-the-art method of manufacturing the energy attenuation assembly2000, including an additive manufacturing process, by selecting 50.26.

Alternatively, if the operator or player selects custom shaped energyattenuation assembly 3000 in step 50.22, then the system will ask theuser to input/acquire/collect shape information about the player's bodypart and specifically the player's head region. This shape informationwill be utilized by the system in the following steps to select theenergy attenuation assembly 2000 that will best fit the player's headand then to modify the selected energy attenuation assembly 2000 tocreate a custom energy attenuation assembly 3000. Next, the operator orplayer may select how the energy attenuation assembly 3000 ismanufactured. For example, the operator or player may select: (i) anadvanced method of manufacturing the energy attenuation assembly,including the custom molding process (e.g. the process disclosed withinU.S. patent application Ser. No. 15/655,490), by selecting 50.24 or (ii)a state-of-the-art method of manufacturing the energy attenuationassembly 3000, including an additive manufacturing process, by selecting50.26.

Next, if the operator or player selected the additive manufacturedenergy attenuation assembly 2000, 3000 or the custom molded energyattenuation assembly by selecting 50.24, 50.26, the operator or playercan then select the energy attenuation assembly performance type insteps 50.28, 50.30, 50.32, 50.34, 50.36. Specifically, the operator orplayer can choose from one of the following performance types: (i)standard 50.28, (ii) type 1 (e.g., position specific) 50.30, (iii) type2 (e.g., playing level specific) 50.32, (iv) type 3 (e.g., position andplaying level specific) 50.34, or (v) custom (e.g., custom based on thespecific player's playing level, position, and playing style) 50.36. Ifthe operator or player selects type custom 50.36, then the system 1 willask the user to input/acquire/collect impact information about theplayer. This impact information will be utilized by the system in thefollowing steps to: (i) select the energy attenuation assembly 2000 thatbest matches the player's player style or (ii) select the energyattenuation assembly 2000 that best matches the player's player styleand then to modify the selected energy attenuation assembly 2000 tocreate a custom energy attenuation assembly 3000.

As will be discussed in greater detail below, a position-specific energyattenuation assembly 2000, 3000 that is designed for a quarterback mayhave additional material in the rear of the energy attenuation assembly2000, 3000 in comparison to a position-specific energy attenuationassembly 2000, 3000 that is designed for a lineman. Likewise, aposition-specific energy attenuation assembly 2000, 3000 that isdesigned for a lineman may include a material that is softer or lessdense in the front of the energy attenuation assembly 2000, 3000 incomparison to a position-specific energy attenuation assembly 2000, 3000that is designed for a quarterback. Also, a playing level specificenergy attenuation assembly 2000, 3000 that is designed for a youthplayer may include additional material and/or may be made from amaterial that is softer or less dense than an energy attenuationassembly 2000, 3000 that is designed for an NFL player.

Alternatively, if the operator or player picks a new helmet 1000 byselecting 50.50, the operator or player will be asked to select a helmettype 50.52. Specifically, the operator or player will be asked to choosefrom the available helmets, where one type may be Riddell's Speed helmet50.54, a second type may be Riddell's SpeedFlex helmet 50.56, and athird type may be another type of helmet 50.58. It should be understoodthat more or less helmet shell designs may be provided to the operatoror player. Next, step 50.60 allows the operator or player to select thetopography or shape of the inner surface of the energy attenuationassembly 2000, 3000. In particular, the player may select: (i) a stockshaped energy attenuation assembly 2000 by selecting 50.62 or (ii) acustom shaped energy attenuation assembly 3000 by selecting 50.66. Ifthe operator or player picks the stock shaped energy attenuationassembly 2000 by selecting 50.62, then the system will ask the user toinput/acquire/collect shape information about the player's body part andspecifically the player's head region. Next, the operator or player mayselect how the energy attenuation assembly 2000 is manufactured. Forexample, the operator or player may select: (i) a standard method ofmanufacturing the energy attenuation assembly, including foam molding,by selecting 50.64 or (ii) a state-of-the-art method of manufacturingthe energy attenuation assembly 2000, including an additivemanufacturing process, by selecting 50.70.

Alternatively, if the operator or player selects custom shaped energyattenuation assembly 3000 in step 50.66, then the system will ask theuser to input/acquire/collect shape information about the player's bodypart and specifically the player's head region. Next, the operator orplayer may select how the energy attenuation assembly 3000 ismanufactured. For example, the operator or player may select: (i) anadvanced method of manufacturing the energy attenuation assembly,including the custom molding process (e.g, the process disclosed withinU.S. patent application Ser. No. 15/655,490), by selecting 50.68 or (ii)a state-of-the-art method of manufacturing the energy attenuationassembly 3000, including an additive manufacturing process, by selecting50.70.

Next, if the operator or player selected the additive manufacturedenergy attenuation assembly 2000, 3000 or the custom molded energyattenuation assembly by selecting 50.68, 50.70, the operator or playercan then select the energy attenuation assembly performance type insteps 50.72, 50.74, 50.76, 50.78, 50.80. Specifically, the operator orplayer can choose from one of the following performance types: (i)standard 50.72, (ii) type 1 (e.g., position specific) 50.74, (iii) type2 (e.g., playing level specific) 50.76, (iv) type 3 (e.g., position andplaying level specific) 50.78, or (v) custom (e.g., custom based on thespecific player's playing level, position, and playing style) 50.80. Ifthe operator or player selects type custom 50.80, then the system 1 willask the user to input/acquire/collect impact information about theplayer. This impact information will be utilized by the system 1 in thefollowing steps to: (i) select the energy attenuation assembly 2000 thatbest matches the player's player style or (ii) select the energyattenuation assembly 2000 that best matches the player's player styleand then to modify the selected energy attenuation assembly 2000 tocreate a custom energy attenuation assembly 3000.

Next, the protective sports helmet configurator allows the operator orplayer to select the faceguard's configuration or shape in 50.82, whichcan include the number and position of both the vertical members andlateral members. In one embodiment, the operator or player may selectthe faceguard's shape from a predetermined plurality of faceguardshapes. In an alternative embodiment, the operator or player can designtheir own faceguard 200 by selecting the placement of specific membersof the faceguard 200. Once the operator or player is done with theircustom designed faceguard, the protective sports helmet configuratorwill test the design and confirm that the design will meet the helmetstandard. If the design will not meet the helmet standard, alternativedesigns to the custom faceguard will be suggested to the operator orplayer.

Next, the protective sports helmet configurator allows the operator orplayer to select the chinstrap type in 50.84. After the chinstrap typeis selected in 50.84, the protective sports helmet configurator allowsthe operator or player to select the color of the shell, faceguard,chinstrap, and energy attenuation assembly 2000, 3000. Once the operatoror player has selected the protective sports helmet from the protectivesports helmet configurator, the protective sports helmet configuratorsends or loads the selected protective sports helmet on a scanningapparatus 110.4.2, 210.4.2. Information about the selected protectivesports helmet will be used by the scanning apparatus 110.4.2, 210.4.2 inorder to determine what type of scan or scans are necessary. Forexample, if the operator or player selected an energy attenuationassembly 2000 that has a non-custom or preset inner topography, then thescanning apparatus 110.4.2, 210.4.2 may determine that the quality ofthe scan does not have to be as high in comparison to a scan needed tomanufacture energy attenuation assembly with a custom inner surface.Alternatively, if the operator or player selected an energy attenuationassembly 2000, 3000 that has a custom performance type, the protectivesports helmet configurator will check to ensure that the system hasenough data about the player's playing style to design this energyattenuation assembly 2000, 3000.

C. Collecting Information

After the desired protective sports helmet is selected in step 50, themulti-step method 1 continues by collecting information about the playerin steps 100, 110, 210, 300, which may include information about theshape of a player's head and the impacts the player receives whileparticipating in the sport.

1. Collecting Impact Information

Referring to FIG. 1, steps 100, 300 describe acquiring information aboutimpacts the players experience while participating in an activity (e.g.,playing a football game). One example of a method of collecting thisimpact information is described within FIGS. 3A-3B. In step 100.2,200.2, an impact sensor system is utilized to carry out the steps in themethod shown in FIGS. 3A-3B. FIG. 4 illustrates an exemplary system100.2, 300.2 that includes: (i) helmets 1000 that each have an in-helmetunit (IHU) 100.2.4, 300.2.4, (ii) a receiving device 100.2.6, 300.2.6,which in this embodiment may be an alerting unit 100.2.6.2, 300.2.6.2,(iii) a remote terminal 100.2.8, 300.2.8, (iv) a team database 100.2.10,300.2.10, and (v) a national database 100.2.12, 300.2.12. The IHU100.2.4, 300.2.4 may be specifically designed and programmed to: (i)measure and record impact information, (ii) analyze the recordedinformation using the algorithm shown in FIGS. 3A-3B, and (iii)depending on the outcome of the algorithm shown in FIGS. 3A-3B, transmitthe recorded information to a receiving device 100.2.6, 300.2.6 that isremote from the THU 100.2.4, 300.2.4.

FIG. 5 illustrates an exemplary schematic of the THU 100.2.4, 300.2.4.As shown, the control module 100.2.4.2, 300.2.4.2 is connected to eachsensor 100.2.4.4 a-e, 300.2.4.4 a-e via separate leads 100.2.4.6 a-e,300.2.4.6 a-e. The five distinct sensors 100.2.4.4 a-e, 300.2.4.4 a-emay be placed at the following locations on a player's head: top, left,right, front, and back. The control module 100.2.4.2, 300.2.4.2 includesa signal conditioner 100.2.4.8, 300.2.4.8, a filter 100.2.4.10,300.2.4.10, a microcontroller or microprocessor 100.2.4.12, 300.2.4.12,a telemetry element 100.2.4.14, 300.2.4.14, an encoder 100.2.4.16,300.2.4.16, and a power source 100.2.4.18, 300.2.4.18. The controlmodule 100.2.4.2, 300.2.4.2 includes a shake sensor 100.2.4.20,300.2.4.20 that may be used to turn the IHU 100.2.4, 300.2.4 ON or OFFbased on a specific shake pattern of the player helmet 20.Alternatively, the IHU 100.2.4, 300.2.4 may have control buttons, suchas a power button and a configuration button, for example. Additionalinformation about the positioning and configuration of the IHU 100.2.4,300.2.4 is described within U.S. Pat. No. 10,105,076 and U.S.Provisional Application 62/364,629, both of which are fully incorporatedherein by reference.

Returning to FIG. 3A, the IHU 100.2.4, 300.2.4 continually monitors fora value from any sensor 100.2.4.4 a-e, 300.2.4.4 a-e that exceeds apredetermined noise threshold, which is programmed into the IHU 100.2.4,300.2.4. As shown in step 100.4, 300.4, once the IHU 100.2.4, 300.2.4determines that a sensor 100.2.4.4 a-e, 300.2.4.4 a-e has recorded avalue that is greater than the predetermined noise threshold, then animpact has been detected. The microcontroller 100.2.4.12, 300.2.4.12wakes up to record information from all sensors 100.2.4.4 a-e, 300.2.4.4a-e and perform both algorithms shown in FIGS. 3A-3B. The firstalgorithm or head impact exposure (HIE) algorithm 100.10, 300.10 doesnot weight the impact magnitude value based on the location of theimpact, while the second algorithm or alert algorithm 100.50, 300.50weights the impact magnitude value based on the location of the impact.The first algorithm or HIE algorithm 100.10, 300.10 compares the impactmagnitude value to a 1^(st) threshold or an impact matrix threshold instep 100.10.2, 300.10.2. The 1^(st) threshold or an impact matrixthreshold is set between 1 g and 80 gs and preferably between 5 gs and30 gs. If the impact magnitude value is less than the impact matrixthreshold, than the microcontroller 100.2.4.12, 300.2.4.12 willdisregard the impact magnitude value shown in step 100.10.10, 300.10.10.However, if the impact magnitude value is greater than the impact matrixthreshold, than the microcontroller 100.2.4.12, 300.2.4.12 will add theimpact magnitude value to the impact matrix in step 100.10.4, 300.10.4.

An exemplary player impact matrix 120.2.75, 320.2.75 is shown in FIG.13. Specifically, the exemplary impact matrix 120.2.75, 320.2.75 iscomprised of 5 columns and 7 rows, where the 5 columns correspond to thelocation of the impact on the player's head (e.g., front, back, left,right, and top) and the 7 rows correspond to the severity of the impact(e.g., 1^(st), 2^(nd), 3^(rd), 4^(th), 5^(th) severity, single impactalert, or cumulative impact alert). Each of these severity values (e.g.,1^(st), 2^(nd), 3^(rd), 4^(th) or 5^(th)) corresponds to a range ofimpact magnitude values. For example, the 1^(st) range may includeimpact magnitude values between the impact matrix threshold and the50^(th) percentile of historical impact magnitude values for players ofsimilar position and playing level. The 2^(nd) range may include impactmagnitude values between the 51^(st) percentile and the 65^(th)percentile of historical impact magnitude values for players of similarposition and playing level. The 3^(rd) range may include impactmagnitude values between the 66^(th) percentile and the 85^(th)percentile of historical impact magnitude values for players of similarposition and playing level. The 4^(th) range may include impactmagnitude values between the 86^(th) percentile and the 95^(th)percentile of historical impact magnitude values for players of similarposition and playing level. The 5^(th) range may include impactmagnitude values above the 95^(th) percentile of historical impactmagnitude values for players of similar position and playing level. Thesingle impact alerts and the cumulative impact alerts are based upon asecond algorithm or alert algorithm 100.50, 300.50. It should beunderstood that these percentile ranges are based on historical impactmagnitude values that have been collected using the proprietarytechnologies owned by the assignee of the present Application and aredisclosed in U.S. Pat. Nos. 10,105,076, 9,622,661, 8,797,165, and8,548,768, each of which is fully incorporated by reference herein. Itshould be understood that these values may be updated in light ofadditional impact information that has been collected by this system orother similar systems.

Returning to FIG. 3A, once the microcontroller 100.2.4.12, 300.2.4.12has added the impact magnitude value to the impact matrix in step100.10.4, 300.10.4, the microcontroller 100.2.4.12, 300.2.4.12determines if a 1^(st) predefined amount of time or an impact matrixtransmit time period has passed from the time the IHU 100.2.4, 300.2.4last transmitted the impact matrix to a receiving device 100.2.6,300.2.6. The impact matrix transmit time period may be set to any time,preferably it is set between one second and 90 days and most preferablybetween 30 seconds and 1 hour. If the amount of time that has passedsince the unit last transmitted the impact matrix to a receiving device100.2.6, 300.2.6 is less than the impact matrix transmit time period,then the microcontroller 100.2.4.12, 300.2.4.12 will perform noadditional steps, as shown in step 100.10.10, 300.10.10. However, if theamount of time that has passed since the unit last transmitted theimpact matrix to a receiving device 100.2.6, 300.2.6 is greater than theimpact matrix transmit time period, then the control module 100.2.4.2,300.2.4.2 of the THU 100.2.4, 300.2.4 will transmit the impact matrixfrom the THU 100.2.4, 300.2.4 to a receiving device 100.2.6, 300.2.6(e.g., an alert unit 100.2.6.2, 300.2.6.2) in step 536. Upon thecompletion of this decision, the THU 100.2.4, 300.2.4 has finishedperforming the HIE algorithm 100.10, 300.10.

While the THU 100.2.4, 300.2.4 is performing the HIE algorithm 100.10,300.10, the THU 100.2.4, 300.2.4 is also performing the alert algorithm100.50, 300.50 shown in FIG. 3B. Referring to FIG. 3B, themicrocontroller 100.2.4.12, 300.2.4.12 will calculate an impact value instep 100.50.2, 300.50.2. In one embodiment, this is done by firstdetermining the linear acceleration, rotational acceleration, headinjury criterion (HIC), and the Gadd severity index (GSI) for the givenimpact. The algorithms used to calculate these values are described inCrisco J J, et al. An Algorithm for Estimating Acceleration Magnitudeand Impact Location Using Multiple Nonorthogonal Single-AxisAccelerometers. J BioMech Eng. 2004; 126(1), Duma S M, et al. Analysisof Real-time Head Accelerations in Collegiate Football Players. ClinSport Med. 2005; 15(1):3-8, Brolinson, P. G., et al. Analysis of LinearHead Accelerations from Collegiate Football Impacts. Current SportsMedicine Reports, vol. 5, no. 1, 2006, pp. 23-28, and Greenwald R M, etal. Head impact severity measures for evaluating mild traumatic braininjury risk exposure. Neurosurgery. 2008; 62(4):789-798, the disclosureof which is hereby incorporated by reference in its entirety for allpurposes. Once the linear acceleration, rotational acceleration, headinjury criterion (HIC), and the Gadd severity index (GSI) are calculatedfor a given impact, these scores are weighted according to the algorithmset forth in Greenwald R M, et al. Head impact severity measures forevaluating mild traumatic brain injury risk exposure. Neurosurgery.2008; 62(4):789-798, the disclosure of which is hereby incorporated byreference in its entirety for all purposes. This resulting weightedvalue is a HITsp value for the given impact, which will be thecalculated impact value in this first embodiment. While not diagnosticof injury, HITsp has been shown to be more sensitive and specific todiagnose concussions than any of the component measures alone.Specifically, HITsp has been shown to be 50% more sensitive to predict asubsequently diagnosed concussion than the usage of any individualmeasure by itself (e.g., linear acceleration).

In another embodiment, the calculated impact value may be equal to thelinear acceleration for the given impact. In a further embodiment, thecalculated impact value may be equal to the HIC score for the givenimpact. In another embodiment, the calculated impact value may be equalto the rotational acceleration for a given impact. In anotherembodiment, the impact value may be equal to the linear accelerationweighted by a combination of impact location and impact duration. Inanother embodiment, the impact value may be equal to the weightedcombination of linear acceleration, rotational acceleration, HIC, GSI,impact location, impact duration, impact direction. In anotherembodiment, the impact value may be equal to a value that is determinedby a learning algorithm that is taught using historical information anddiagnosed injuries. In even a further embodiment, the impact value maybe equal to any combination of the above.

Referring to FIG. 3B, once the impact value is calculated in step100.50.2, 300.50.2 by the microcontroller 100.2.4.12, 300.2.4.12, theimpact value is compared against a 2^(nd) threshold or high magnitudeimpact threshold in step 100.50.4, 300.50.4. This high magnitude impactthreshold may be set to the 95^(th) percentile for impacts recorded byplayers of similar playing level (e.g., youth, high school, college andprofessional players) and similar position (e.g., offensive line,running backs, quarterback, wide receivers, defensive linemen,linebackers, defensive backs and special teams). If the impact value isless than the high magnitude impact threshold, than the microcontroller100.2.4.12, 300.2.4.12 will not perform any additional operations, asshown in step 100.50.6, 300.50.6. However, if the impact value isgreater than the high magnitude impact threshold, than the impact valuewill be added to the cumulative impact value in step 100.50.6, 300.50.6and compared against a 3^(rd) threshold or single impact alert thresholdin step 100.50.18, 300.50.18. This single impact alert threshold may beset to the 99^(th) percentile for impacts recorded by players of similarplaying level and position. It should be understood that all percentiles(e.g., 95^(th) and 99^(th)) contained in this application are based onhistorical impact magnitude values that have been collected using theproprietary technologies owned by the assignee of the presentApplication and are disclosed in U.S. Pat. Nos. 10,105,076, 9,622,661,8,797,165, and 8,548,768, each of which is fully incorporated byreference herein. However, it should be understood that thesepercentiles may be updated in light of additional impact informationthat has been collected by this system or other systems.

Referring to FIG. 3B, if the impact value is greater than the singleimpact alert threshold, the control module 100.2.4.2, 300.2.4.2transmits alert information that is associated with the single impactalert to the receiving device 100.2.6, 300.2.6 (e.g., an alert unit100.2.6.2, 300.2.6.2) in step 100.50.22, 300.50.22. The alertinformation may include, but is not limited to: (i) the impact value(e.g., graphical or non-graphical display of the magnitude of theimpact), (ii) impact location (e.g., graphical or non-graphical), (iii)impact time, (iv) impact direction, (v) player's unique identifier, (vi)alert type, (vii) player's heart rate, (viii) player's temperature and(ix) other relevant information. If the impact value is less than thesingle impact alert threshold, the microcontroller 100.2.4.12,300.2.4.12 will not perform any additional steps 100.50.20, 300.50.20along this path of the algorithm 100.50, 300.50.

While the microcontroller 100.2.4.12, 300.2.4.12 is determining whetherthe impact value is greater than the single impact alert threshold instep 100.50.18, 300.50.18, the microcontroller 100.2.4.12, 300.2.4.12also calculates a weighted cumulative impact value that includes thisnew impact value, in step 100.50.10, 300.50.10 shown in FIG. 3B.Specifically, the weighted cumulative impact value is calculated basedon a weighted average of every relevant impact value that is over a2^(nd) threshold or high magnitude impact threshold. To determine thisweighted average, every impact value that is over a 2^(nd) threshold isweighted by a decaying factor. For example, an impact that was recorded4 days ago maybe multiplied by 0.4 decaying factor, thereby reducing themagnitude level of this impact. After the weighted impact values aredetermined, these values are summed together to generate the weightedcumulative impact value. It should be understood that themicrocontroller 100.2.4.12, 300.2.4.12 will exclude irrelevant impactvalues that are old enough to cause their weighted impact value to bezero due to the decaying factor. For example, if the decaying factor foran impact that is over 7 days old is 0; then regardless of the impactvalue, this impact is irrelevant to this calculation and will not beincluded within this calculation. One skilled in the art recognizes thatweighting variables (e.g., time window, decay function, input threshold)are adjustable.

Once the weighted cumulative impact value has been calculated in step100.50.10, 300.50.10 in FIG. 3B, this value is compared against a 4^(th)threshold or a cumulative impact alert threshold in step 100.50.12,300.50.12. This cumulative impact alert threshold may be set to the95^(th) percentile for weighted cumulative impact values recorded byplayers of similar playing level and position. If the weightedcumulative impact value is less than the cumulative impact alertthreshold, than the microcontroller 100.2.4.12, 300.2.4.12 will notperform any additional steps 100.50.16, 300.50.16. However, if theweighted cumulative impact value is greater than the cumulative impactvalue threshold, the control module 100.2.4.2, 300.2.4.2 of the IHU100.2.4, 300.2.4 transmits alert information that is associated with acumulative impact alert to the receiving device 100.2.6, 300.2.6 (e.g.,an alert unit 100.2.6.2, 300.2.6.2) in step 100.50.14, 300.50.14. Asdiscussed above, the alert information may include, but is not limitedto: (i) the impact value (e.g., graphical or non-graphical display ofthe magnitude of the impact), (ii) impact location (e.g., graphical ornon-graphical), (iii) impact time, (iv) impact direction, (v) player'sunique identifier, (vi) alert type, (vii) player's heart rate, (viii)player's temperature and (ix) other relevant information. Upon thecompletion of this decision, the IHU 100.2.4, 300.2.4 has finishedperforming the alert algorithm 100.50, 300.50.

Referring to FIG. 4, once the HIE algorithm 100.10, 300.10 and the alertalgorithm 100.50, 300.50 are performed, the IHU 100.2.4 uses thetelemetry module 100.2.4.14, 300.2.4.14 to wirelessly transmit impactinformation to the receiving unit 100.2.6, 300.2.6 via communicationlinks 100.2.5, 300.2.5. Specifically, the communication link 100.2.5,300.2.5 may be based on any type of wireless communication technologies.These wireless communication technologies may operate in an unlicensedband (e.g., 433.05 MHz-434.79 MHz, 902 MHz-928 MHz, 2.4 GHz-2.5 GHz,5.725 GHz-5.875 GHz) or in a licensed band. A few examples of wirelesscommunication technologies that that may be used, including but notlimited to, Bluetooth, ZigBee, Wi-Fi (e.g., 802.11a, b, g, n), Wi-Fi Max(e.g., 802.16e), Digital Enhanced Cordless Telecommunications (DECT),cellular communication technologies (e.g., CDMA-1X, UMTS/HSDPA,GSM/GPRS, TDMA/EDGE, EV/DO, or LTE), near field communication (NFC), ora custom designed wireless communication technology. In otherembodiments that are not shown, the telemetry module 100.2.4.14,300.2.4.14 may include both wired and wireless communicationtechnologies. A few examples of wired communication technologies thatmay be used, include but are not limited to, any USB basedcommunications link, Ethernet (e.g., 802.3), FireWire, or any other typeof packet based wired communication technology.

As shown in FIG. 4, the receiving device 100.2.6, 300.2.6 includes atelemetry module (not shown) that is configured to communicate with thetelemetry module 100.2.4.14, 300.2.4.14 to enable the impact informationthat is generated by the HIE algorithm 100.10, 300.10 and the alertalgorithm 100.50, 300.50 to be transferred to the receiving device100.2.6, 300.2.6. To enable this communication, the telemetry modulecontained within the receiving device 100.2.6, 300.2.6 may utilize anyof the above technologies that are described in connection with thetelemetry module 100.2.4.14, 300.2.4.14. Once the impact information isreceived by the receiving device 100.2.6, 300.2.6, it can process thisinformation to display relevant data to sideline personnel (e.g.,trainer). This relevant data may include: (i) the impact value (e.g.,graphical or non-graphical display of the magnitude of the impact), (ii)impact location (e.g., graphical or non-graphical), (iii) impact time,(iv) impact direction (e.g., graphical or non-graphical), (v) player'sunique identifier (e.g., name or jersey number), (vi) alert type, (vii)player's heart rate, (viii) player's temperature, (ix) impact magnitudefrom the impact matrix, and/or (x) other relevant information. It shouldbe understood that the receiving device 100.2.6, 300.2.6 may be aportable hand-held unit that is typically carried by a person that is:(i) positioned proximate (e.g., within 50 yards) to the field orlocation that the physical activity is taking place and (ii) is notengaged in the physical activity (e.g., sideline personnel, which may bea trainer). Non-limiting examples of receiving devices 100.2.6, 300.2.6include: PDAs, cellular phones, watches, tablets, or custom designedalert units 100.2.6.2, 300.2.6.2.

Referring to FIG. 4, once the impact information has been received bythe receiving device 100.2.6, 300.2.6, the impact information may becommunicated via link 100.2.7, 300.2.7 to the remote terminal 100.2.8,300.2.8 for additional analysis. This communication link 100.2.7,300.2.7 between the receiving device 100.2.6, 300.2.6 and remoteterminal 100.2.8, 300.2.8 may be wireless or wired and may utilize anyof the above described technologies. The remote terminal 100.2.6,300.2.6 is typically not proximate to the field, nor is it carried by atrainer during the activity. Instead, the remote terminal 100.2.6,300.2.6 is typically left in a secured location that is accessibleshortly after the activity has been completed. Once the impactinformation is transferred from the receiving device 100.2.6, 300.2.6 tothe remote terminal 100.2.8, 300.2.8, the remote terminal 100.2.8,100.2.8 can upload the information to the team database 100.2.10,300.2.10 via communications link 100.2.9, 300.2.9 or national database100.2.12, 300.2.12 via communications link 100.2.14, 300.2.14. The teamdatabase 100.2.10, 300.2.10 is utilized to store information that isrelevant to the team. In addition to the impact information, thisrelevant information may include: (i) practice calendars/schedules, (ii)equipment assignments and profiles (e.g., relevant sizes, type of shoes,type of helmet, type of energy attenuation assembly, type of chin strap,type of faceguard, and etc.), (iii) medical data for each player (e.g.,medical histories, injuries, height, weight, emergency information, andetc.), (iv) statistics for each player (e.g., weight lifting records, 40yard dash times, and etc.), (v) workout regiments for each player, (vi)information about the shape of the players body parts (e.g., head), and(vii) other player data (e.g., contact information).

The national database 100.2.12, 300.2.12 stores all the information or asubset of the data that is stored in each of the team databases100.2.10, 300.2.10 around the nation or world. Specifically, the teamdatabases 100.2.10, 300.2.10 upload a copy of the information to thenational database 100.2.12, 300.2.12 via communications link 100.2.13,300.2.13 after a predefined amount of time has passed since the teamdatabase 100.2.10, 300.2.10 was last uploaded to the national database100.2.12, 300.2.12. Additionally, after the new data from the teamdatabase 100.2.10, 300.2.10 is uploaded to the national database100.2.12, 300.2.12, the team database 100.2.10, 300.2.10 may downloadnew thresholds from the national database 100.2.12, 300.2.12 viacommunications link 100.2.14, 300.2.14. The data that may be containedwithin the national database 100.2.12, 300.2.12 may include, but is notlimited to: (i) single and cumulative alerts for each player across thenation/world, (ii) impact matrix for each player across thenation/world, (iii) other data related to the recorded physiologicalparameters for each player across the nation/world, (iv) equipmentassignments and profiles of each player across the nation/world (e.g.,relevant sizes, type of shoes, type of helmet, type of energyattenuation assembly, type of chin strap, type of faceguard, and etc.),(v) medical data for each player across the nation/world (e.g., medicalhistories, injuries, height, weight, emergency information, and etc.),(vi) statistics for each player across the nation/world (e.g., weightlifting records, 40 yard dash times, and etc.), (vii) workout regimentsfor each player across the nation/world, (viii) information about theshape of the players body parts (e.g., head), and (ix) other player dataacross the nation/world (e.g., contact information). It should also beunderstood that the national database 100.2.12, 300.2.12 contains datathat has been collected over many years and it includes at least thedata collected using the proprietary technologies owned by the assigneeof the present application, which is disclosed in U.S. Pat. Nos.10,105,076, 9,622,661, 8,797,165, and 8,548,768, each of which is fullyincorporated by reference herein. For example, this national database100.2.12, 300.2.12 currently includes data related to nearly six millionimpacts. While FIG. 4 shows that the remote terminal 100.2.8, 100.2.8 isseparate from: (i) receiving device 100.2.6, 300.2.6, (ii) team database100.2.10, 300.2.10, and (iii) a national database 100.2.12, 300.2.12, itshould be understood that in an alternative embodiment these may all becombined together or partially combined together.

2. Collecting Shape Information

In addition to impact information, it may be desirable to collectinformation about the shape of player's heads to aid in designing theprotective sports helmet 1000. Referring to FIG. 1, steps 110, 210describe the acquisition of information about the shape of a player'sbody part (e.g., head). An exemplary method of collecting this shapeinformation is described within FIGS. 6A-6B. This method commences instep 110.2, 210.2 by opening a software application 110.4.4, 210.4.4(exemplary embodiment shown in FIG. 9) in step 110.4, 210.4 on, or incommunication with, a scanning apparatus 110.4.2, 210.4.2 (exemplaryembodiment shown in FIGS. 7, 9 and 11). Referring back to FIG. 6A, uponopening the software application 110.4.4, 210.4.4, the operator isprompted in step 110.6, 210.6 to select a player from a list of playersor enter information about the player (e.g., name, age, playing level,position, etc.).

After the player information is entered in step 110.6, 210.6, thesoftware application 110.4.4, 210.4.4 prompts the operator to instructand then check that the player P has properly placed the scanning hood110.8.2, 210.8.2 (exemplary embodiment shown in FIG. 7) on, or over, thehead H of the player P in step 110.8, 210.8. The scanning hood 110.8.2,210.8.2 may be a flexible apparatus sized to fit over the player's headH and achieve a tight or snug fit around the player's head H due toelastic properties and dimensions of the scanning hood 110.8.2, 210.8.2,as can be seen in FIG. 7. The scanning hood 110.8.2, 210.8.2 providesfor increased accuracy when performing the information acquisitionprocess by conforming to the anatomical features of the player's head Hand facial region F, namely the topography and contours of the head Hand facial region F while reducing effects of hair. The scanning hood110.8.2, 210.8.2 may be made from neoprene, lycra or any other suitableelastic material known to those skilled in the art. It should beunderstood that the term scanning hood 110.8.2, 210.8.2 does not justrefer to a hood that is placed over the head H of the player P; instead,it refers to a snug fitting item (e.g., shirt, armband, leg band, oretc.) that has minimal thickness and is placed in direct contact withthe player's body part in order to aid in the collection of shapeinformation.

As shown in FIGS. 7-8, one or more reference markers 110.8.2.2.2,210.8.2.2.2 may be placed on the scanning hood 110.8.2, 210.8.2. Thereference markers 110.8.2.2.2, 210.8.2.2.2 may be used to aid in theorientation and positioning of the images or video of the scanning hood110.8.2, 210.8.2, as will be described below. The reference markers110.8.2.2.2, 210.8.2.2.2 may be: (i) colored, (ii) offset (e.g., raisedor depressed) from other portions of the scanning hood 110.8.2, 210.8.2,(iii) include patterns or textures, (iv) or include electronicproperties or features that aid in collection the of shape informationby the scanning apparatus 110.4.2, 210.4.2. These reference markers110.8.2.2.2, 210.8.2.2.2 may be printed on the scanning hood 110.8.2,210.8.2 or maybe a separate item that is attached to the scanning hood110.8.2, 210.8.2 using adhesives or using any other mechanical orchemical attachment means. The number of reference markers 110.8.2.2.2,210.8.2.2.2 that are used should balance the need for an accuratecollection of shape information on one hand with processing times on theother hand. In one exemplary embodiment, twelve reference markers110.8.2.2.2, 210.8.2.2.2 per square inch may be used. A person skilledin the art recognizes that more or fewer reference markers 110.8.2.2.2,210.8.2.2.2 may be used to alter the processing times and the accuracyof the shape information. In a further embodiment, it should beunderstood that the scanning hood 110.8.2, 210.8.2 may not have anyreference markers 110.8.2.2.2, 210.8.2.2.2.

In alternative embodiments, a scanning hood 110.8.2, 210.8.2 may not beused when collecting shape information in certain situations. Forexample, scanning hood 110.8.2, 210.8.2 may not be needed to reduce theeffects of hair when capturing shape information about a player's foot,arm, or torso. In embodiments where a scanning hood 110.8.2, 210.8.2 isnot used, then one or more reference markers 110.8.2.2.2, 210.8.2.2.2may be directly placed on the player's body part. For example, the oneor more reference markers 110.8.2.2.2, 210.8.2.2.2 may have a removablecoupling means (e.g., adhesive) that allows them to be removably coupledto the player's body part to aid in the collection of the shapeinformation.

Referring to FIG. 6A, after the player P and/or the operator determinesthat the scanning hood 502 is properly positioned on the player's head Hin step 110.8, 210.8, the operator is prompted to start the informationacquisition process in step 110.10, 201,10. The information acquisitionprocess may require different steps depending on the configuration ofthe scanning apparatus 110.4.2, 210.4.2 and the technology that isutilized by the scanning apparatus 110.4.2, 210.4.2. In one exemplaryembodiment, the scanning apparatus 110.4.2, 210.4.2 may be a hand-heldunit (e.g., personal computer, tablet or cellphone) that includes anon-contact camera based scanner. In this embodiment, the operator willwalk around the player with the scanning apparatus 110.4.2, 210.4.2 tocollect images or video frames of the player. The scanning apparatus110.4.2, 210.4.2 or a separate device will be used to process theacquired shape information using photogrammetry techniques and/oralgorithms. It should be understood that the shape information may bestored, manipulated, altered, and displayed in multiple formats,including numerical values contained within a table, points arranged in3D space, partial surfaces, or complete surfaces.

In an alternative embodiment, the scanning apparatus 110.4.2, 210.4.2may be a hand-held unit (e.g., personal computer, tablet or cellphone)that includes a non-contact LiDAR or time-of-flight sensor. In thisembodiment, the operator will walk around the player with thenon-contact LiDAR or time-of-flight sensor. In particular, the LiDAR ortime-of-flight sensor sends and receives light pulses in order to createa point cloud that contains shape information. In an alternativeembodiment that is not shown, the scanning apparatus 110.4.2, 210.4.2may be a stationary unit that contains a non-contact light or soundbased scanner (e.g., camera, LiDAR, etc.). In this embodiment, thelight/sound sensors can capture the shape information in a singleinstant (e.g., multiple cameras positioned around the person that canall operate at the same time) or light/sound sensors may capture theshape information over a predefined period of time by the stationaryunit's ability to move its sensors around the player P. In an evenfurther embodiment that is not shown, the scanning apparatus may be astationary contact based scanner assembly. In this embodiment, once thecontact sensors are placed in contact with the player's body part, theycan capture the shape information in a single instant (e.g., multiplepressure sensors may be positioned in contact with the player's bodypart to enable the collection of the shape information at one time). Inanother embodiment, the scanning apparatus may be a non-stationarycontact based scanner. In this embodiment, the scanning apparatus mayinclude at least one pressure sensor may capture the shape informationover a predefined period of time by moving the pressure sensor over theplayer's body part. In other embodiments, shape information may becollected using: (i) computed tomography or magnetic resonance imaging,(ii) structured-light scanner, (iii) triangulation based scanner, (iv)conoscopic based scanner, (v) modulated-light scanner, (vi) anycombination of the above techniques and/or technologies, or (vii) anytechnology or system that is configured to capture shape information.For example, the hand-held scanner may utilize both a camera and atime-of-flight sensor to collect the shape information.

FIG. 10 shows an electronic device 10, which is displaying an exemplarypath that the scanning apparatus 110.4.2, 210.4.2 may follow during theacquisition of shape information. The electronic device 10 is acomputerized device that has an input device 12 and a display device 14.The electronic device 10 may be a generic computer or maybe aspecialized computer that is specifically designed to perform thecomputations necessary to carry out the processes that are disclosedherein. It should be understood that the electronic device 10 may not becontained within a single location and instead may be located at aplurality of locations. For example, the computing extent of theelectronic device may be in a cloud server, while the display 14 andinput device 12 are located in the office of the designer and can beaccessed via an internet connection.

Referring back to FIG. 10, the hand-held scanning apparatus 110.4.2,210.4.2 is shown in approximately 40 different locations around aplayer's head H. These approximately 40 different positions are atdifferent angles and elevations when compared to one another. Placingthe scanning apparatus 110.4.2, 210.4.2 in these different locationsduring the acquisition of shape information helps ensure that theinformation that will later be made from this acquisition process doesnot have gaps or holes contained therein. It should be understood thatthe discrete locations are shown in FIG. 10 are exemplary and are simplyincluded herein to illustrate the path that the scanning apparatus110.4.2, 210.4.2 may follow during the acquisition of shape information.There is no requirement that the scanning apparatus 110.4.2, 210.4.2pass through these points or pause to gather shape information at thesepoints during the acquisition process.

Referring back to FIG. 6A, during the acquisition of shape information,the software application 110.4.4, 210.4.4 may instruct the operator to:(i) change the speed at which they are moving around the player (e.g.,slow down the pace) to ensure that the proper level of detail iscaptured in step 110.12, 210.12, (ii) change the vertical positionand/or angle of the scanning apparatus 110.4.2, 210.4.2 in step 110.14,210.14, and/or (iii) change the operators position in relation to theplayer P (e.g., move forward or back up from the player) in step 110.14,210.14. Once the acquisition of shape information is completed, thesoftware application 110.4.4, 210.4.4 analyzes the information todetermine if the quality is sufficient to meet the quality requirementsthat are preprogrammed within the software application 110.4.4, 210.4.4.If the quality of the shape information is determined to be sufficientin step 110.18, the software application 110.4.4, 210.4.4 asks theoperator if a helmet scan is desired. An example of where a helmet scanmay be useful is when the player P desires a unique helmetconfiguration, such as if the player decides to have the helmet 1000positioned lower on their head then where a wearer traditionally placesthe helmet 1000. If it is determined that a helmet scan is desired instep 110.30, 210.30, then the operator will start the next stage of theacquiring shape information. The process of acquiring the helmet scan isdescribed in connection with FIG. 6B. If it is determined that a helmetscan is not desired in step 110.18, 210.18, then the softwareapplication 110.4.4, 210.4.4 will send, via a wire or wirelessly, to alocal or remote computer/database (e.g., team database 100.2.10,300.2.10), the shape information in step 110.32, 210.32. This local orremote computer/database may then be locally or remotely accessed bytechnicians/designers who perform the next steps in designing andmanufacturing the helmet 1000.

Alternatively, if the software application 110.4.4, 210.4.4 determinesthat the shape information lacks sufficient quality to meet the qualityrequirements that are preprogrammed within the software application110.4.4, 210.4.4, then the software application 110.4.4, 210.4.4 mayprompt the operator to obtain additional information in steps 110.24,210.24, 110.26, 210.26. Specifically, in steps 110.24, 210.24, thesoftware application 110.4.4, 210.4.4 may graphically show the operator:(i) the location to stand, (ii) what elevation to place the scanningapparatus 110.4.2, 210.4.2, and/or (iii) what angle to place thescanning apparatus 110.4.2, 210.4.2. Once the operator obtains theadditional information at that specific location, the softwareapplication 110.4.4, 210.4.4 then analyzes the original collection ofinformation along with this additional information to determine if thequality of the combined collection of information is sufficient to meetthe quality requirements that are preprogrammed within the softwareapplication 110.4.4, 210.4.4. This process is then repeated until thequality of the information is sufficient. Alternatively, the softwareapplication 110.4.4, 210.4.4 may request that the operator restart theshape information acquisition process. The software application 110.4.4,210.4.4 then analyzes the first collection of shape information alongwith the second collection of shape information to see if thecombination of information is sufficient to meet the qualityrequirements that are preprogrammed within the software application110.4.4, 210.4.4. This process is then repeated until the quality of theinformation is sufficient. After the shape information is determined tobe sufficient, the software application 110.4.4, 210.4.4 performs thestep 110.30, 210.30 of prompting the operator to determine if a helmetscan is desired.

FIG. 6B describes the acquisition of additional shape information usinga scanning helmet 110.36.2, 210.36.2. The first step in this process is110.36, 210.36, which is accomplished by identifying the proper scanninghelmet 110.36.2, 210.36.2. As an example for a player P, the scanninghelmet 110.36.2, 210.36.2 shell sizes may include medium, large andextra-large, although additional or intermediate sizes are certainlywithin the scope of this disclosure. The selection of the scanninghelmet 110.36.2, 210.36.2 shell size may be determined by the positionthe player plays, previous player experiences, or by estimations ormeasurements taken during or before the acquisition of the shapeinformation. It should be understood that the term scanning helmet110.36.2, 210.36.2 does not just refer to a helmet that is placed overthe player's head; instead, it refers to a modified version of the endproduct that is being designed and manufactured according to the methodsdisclosed herein, which aids in the collection of additional shapeinformation.

Once the size of the scanning helmet 110.36.2, 210.36.2 is selected instep 110.36, 210.36, the scanning helmet 110.36.2, 210.36.2 is placedover the player's head H while the player P is wearing the scanning hood110.8.2, 210.8.2 in step 110.40, 210.40. After the scanning helmet110.36.2, 210.36.2 is placed on the player's head H in step 110.40,210.40, the player adjusts the scanning helmet 110.36.2, 210.36.2 to apreferred wearing position or configuration, which includes adjustingthe chin strap assembly by tightening or loosening it. It is notuncommon for a player P to repeatedly adjust the scanning helmet110.36.2, 210.36.2 to attain his or her preferred wearing positionbecause this position is a matter of personal preference. For example,some players prefer to wear their helmet lower on their head H withrespect to their brow line, while other players prefer to wear theirhelmet higher on their head H with respect to their brow line.

As shown in FIG. 11, the scanning helmet 110.36.2, 210.36.2 includes thechin strap 110.36.2.1, 210.36.1, one or more apertures 110.36.2.2,210.36.2 formed in a shell 110.36.2.3, 210.36.3 of the helmet 110.36.2,210.36.2 and an internal scanning energy attenuation assembly110.36.2.4, 210.36.4. The position, number, and shape of the apertures110.36.2.2, 210.36.2.2 in the scanning helmet 110.36.2, 210.36.2 are notlimited by this disclosure. For example, the scanning helmet 110.36.2,210.36.2 may have one aperture 110.36.2.2, 210.36.2.2 that is smallerthan the aperture 110.36.2.2, 210.36.2.2 shown in FIG. 11, the scanninghelmet 110.36.2, 210.36.2 may have twenty apertures that are positionedin various locations throughout the shell, or the scanning helmet110.36.2, 210.36.2 may have three apertures. These apertures 110.36.2.2,210.36.2 allow certain portions of the scanning hood 110.8.2, 210.8.2 tobe seen when the scanning helmet 110.36.2, 210.36.2 is worn over thescanning hood 110.8.2, 210.8.2 on the player's head H. As mentionedabove, the scanning helmet 110.36.2, 210.36.2 includes the faceguardthat is removably attached to a forward portion of the scanning helmet110.36.2, 210.36.2. The faceguard may be used by the player, whenwearing the scanning helmet 110.36.2, 210.36.2, to assist the player indetermining a preferred helmet wearing position. Once the playerpositions the scanning helmet 110.36.2, 210.36.2 such that a preferredhelmet wearing position is achieved, the faceguard is removed toincrease the accuracy of the helmet scan by allowing a scanningapparatus 110.4.2, 210.4.2 to capture a greater, and less obscured, aportion of the player's face. To aid in the attachment and removal ofthe faceguard, easy to open and close clips may be utilized. Althoughthe faceguard is removed, the chin strap assembly remains secured aroundthe player's chin and jaw thereby securing the scanning helmet 110.36.2,210.36.2 in the preferred helmet wearing position.

Referring back to FIG. 6B, after the scanning helmet 110.36.2, 210.36.2is properly positioned on the player's head in steps 110.42, 210.42,110.44, 210.42, the operator is prompted by the software application110.4.4, 210.4.4 to start the information acquisition process. Similarto the above process, the software application 110.4.4, 210.4.4 mayinstruct the operator to: (i) change the speed at which they are movingaround the player (e.g., slow down the pace) to ensure that the properlevel of detail is captured in step 110.48, 210.48, (ii) change thevertical position and/or angle of the scanning apparatus 110.4.2,210.4.2 in step 110.50, 210.50, and/or (iii) change the operatorsposition in relation to the player P (e.g., move forward or back up fromthe player) in step 110.50, 210.50. Once the operator completes theacquisition of additional shape information in step 110.52, 210.52, thesoftware application 110.4.4, 210.4.4 analyzes the information todetermine if the quality of the information is sufficient to meet thequality requirements that are preprogrammed within the softwareapplication 110.4.4, 210.4.4 in step 110.54, 210.54. If the softwareapplication 110.4.4, 210.4.4 determines that the quality of theinformation is sufficient 110.54, 210.54, then the scanning apparatus110.4.2, 210.4.2 will send, via a wire or wirelessly, to a local orremote computer/database (e.g., team database 100.2.10, 300.2.10), theshape information. This local or remote computer/database may then belocally or remotely accessed by technicians who perform the next stepsin designing and manufacturing the helmet 1000.

Alternatively, if the software application 110.4.4, 210.4.4 determinesthat the quality of the shape information lack sufficient quality tomeet the quality requirements that are preprogrammed within the softwareapplication 110.4.4, 210.4.4, then the software application 110.4.4,210.4.4 may prompt the operator to obtain additional information insteps 110.56, 210.56, 110.58, 210.58. Specifically, in step 110.56,210.56 the software application 110.4.4, 210.4.4 may graphically showthe operator: (i) the location to stand, (ii) what elevation to placethe scanning apparatus 504, and/or (iii) what angle to place thescanning apparatus 110.4.2, 210.4.2. Once the operator obtains theadditional shape information at that specific location, the softwareapplication 110.4.4, 210.4.4 will then analyze the original collectionof shape information along with this additional shape information todetermine if the quality of the combined collection of shape informationis sufficient to meet the quality requirements that are preprogrammedwithin the software application 110.4.4, 210.4.4. This process is thenrepeated until the quality of the information is sufficient.Alternatively, the software application 110.4.4, 210.4.4 may requestthat the operator restart the information acquisition process in step110.58, 210.58. The software application 110.4.4, 210.4.4 then analyzesthe first collection of shape information along with the secondcollection of shape information to see if the combination of informationis sufficient to meet the quality requirements that are preprogrammedwithin the software application 110.4.4, 210.4.4. This process is thenrepeated until the quality of the information is sufficient. After theinformation is determined to be sufficient, the software application110.4.4, 210.4.4 performs step 110.62, 210.62. It should be understoodthat some of the steps in the process of acquiring shape information maybe performed in a different order. For example, the acquisition ofinformation in connection with the scanning hood 110.8.2, 210.8.2 may beperformed after the acquisition of information in connection with thescanning helmet 110.36.2, 210.36.2.

D. Create Specific Player Profile

The next step in this multi-step method 1 continues by creating theplayer's profile 120.99, 220.99, 320.99. This player profile 120.99,220.99, 320.99 may include impact information identified in step 120.1,320.1, shape information identified in step 120.50, 320.50, both impactinformation and shape information identified in steps 120.1, 120.50,320.1, 320.50, or some other combination of information about theplayer's attributes.

1. Impact Information for a Specific Player

The impact information for a specific player may be used to generate acomplete impact matrix 120.8.99, 320.8.99 or an impact score by theprocess described within FIG. 12. This process starts by collectingimpact information in step 120.1, 320.1. Referring to FIG. 13, theimpact information may be collected from/using: (i) 120.2.2, 320.2.2,which is the system described above in connection with FIGS. 3A-3B, (ii)120.2.4, 320.2.4, which is the Sideline Response System (SRS) that isdisclosed in connection with U.S. Pat. Nos. 6,826,509; 7,526,389;8,548,768; 8,554,509; 8,797,165; 9,622,661 and 10,292,650, all of whichare fully incorporated herein by reference, (iii) 120.2.6, 320.2.6,which is the InSite Response System that is disclosed in connection withU.S. Pat. No. 10,105,076, which is fully incorporated herein byreference, and/or (iv) 120.2.8, 320.2.8, which are alternative systems(e.g., NFL's impact system).

Referring back to FIG. 12, once this impact information is collected instep 120.1, 320.1, the impact information may be used to generate aplayer impact matrix 120.2.99, 320.2.99 in step 120.2, 320.2.Specifically, the impact matrix 120.2.99, 320.2.99 may include 5 columnsand 7 rows, where the 5 columns correspond to the location of the impacton the player's head (e.g., front, back, left, right, and top) and the 7rows correspond to the severity of the impact (e.g., 1^(st), 2^(nd),3^(rd), 4^(th), 5^(th) severity, single impact alert, or cumulativeimpact alert). An example 120.2.75, 320.2.75 of such an impact matrix120.2.99, 320.2.99 is shown in FIG. 13. The impact information that maybe used to create this matrix 120.2.99, 320.2.99 may be compiled fromall impacts or a subset of the impacts that have been received by aplayer. For example, a subset of the impacts may include impacts thatare over: (i) the predetermined noise threshold, (ii) the 1^(st) impactthreshold or impact matrix threshold, or (iii) the 2^(nd) impactthreshold or high magnitude impact threshold. Additional informationabout this player impact matrix 120.2.99, 320.2.99 is disclosed aboveand may be disclosed within U.S. Provisional Patent Application Ser. No.62/778,559, which is hereby incorporated by reference.

Alternatively, the impact information may be used to generate a playerimpact score in step 120.2, 320.2. The impact information that may beused to create this impact score may be compiled from all impacts or asubset of the impacts that have been received by a player. For example,a subset of the impacts may include impacts that are over: (i) thepredetermined noise threshold, (ii) the 1^(st) impact threshold orimpact matrix threshold, or (iii) the 2^(nd) impact threshold or highmagnitude impact threshold. Once the set of impact information isdetermined, the impact score may be calculated. Specifically, thisimpact score may be calculated by averaging the magnitudes of theimpacts contained within the selected impact information. Alternatively,the impact score may be calculated by averaging the weighted magnitudesof each impact contained within the selected impact information, whereinthe magnitudes are weighted by: (i) the location of the impact (e.g.,side or back of the head has a greater weighting than the front of thehead), (ii) frequency (e.g., ten impacts over a predefined thresholdthat were experienced over one hour has a greater weight than tenimpacts over a predefined threshold over two weeks), (iii) number (e.g.,an increasing multiplier is applied based on an increasing impactmagnitude, which gives higher magnitude impacts greater weight), (iv)duration of the impact, (v) other head injury criteria values orcalculations, (vi) player's specific attributes (e.g., position, weight,height, age, level), or (vii) a combination of these weighting methods.

Once the player's impact matrix 120.2.99, 320.2.99 or impact score aregenerated within step 120.2, 320.2, the impact matrix 120.2.99, 320.2.99or impact score is reviewed to ensure that it is accurate and complete.If the data that is used to generate the impact matrix 120.2.99,320.2.99 or impact score is too incomplete (e.g., does not containenough data to accurately calculate an impact matrix or impact score),then this impact matrix 120.2.99, 320.2.99 or impact score is removedfrom this method 1 and further analysis in step 120.4, 320.4. Next, ifother information (e.g., player's position or level), which isassociated with the impact matrix or impact score is missing, then thisimpact matrix 120.2.99, 320.2.99 or impact score is removed from thisprocess and further analysis in step 120.6, 320.6. If the impact matrix120.2.99, 320.2.99 or impact score is removed for any reason, includingthe above reasons, then the system will try and obtain this informationby searching the team database, sending an inquiry to the coach, sendingan inquiry to the individual player, or trying to obtain thisinformation from another source. Once this missing information isobtained, the helmet selection and/or design of the player's specifichelmet may continue. If this information cannot be obtained, thencertain protective sports helmets may not be available or the selectedprotective sports helmet may not be based on the player's impactinformation. Upon the completion of any one of the following steps120.6, 320.6, the player's impact matrix/player's impact score 120.8.99,320.8.99 are outputted in steps 120.8, 220.8. These outputs form atleast a portion of the player's profile 120.99, 320.99, which isuploaded to a database, local or remote, that can be accessed bytechnicians who perform the next steps in selecting, designing and/ormanufacturing the helmet 1000.

2. Shape Information for a Specific Player

The shape information for a specific player may be used to create acomplete body part model 120.70.99, 220.70.99 by the process describedin FIG. 12. The process of creating this body part model 120.70.99,220.70.99 starts with collecting this information in step 120.50,220.50. Referring to FIG. 14, this information may be generated andstored in connection with: (i) 120.50.2, 220.50.2, which is describedabove in connection with FIGS. 6A-6B, (ii) 120.50.4, 220.50.4, which aresystems that are described within U.S. Pat. No. 10,159,296 and U.S.patent application Ser. No. 15/655,490 that are owned or licensed to theassignee of this application, or (iii) 120.50.6, 220.50.6, which is analternative system. Referring back to FIG. 12, once the collection ofplayer shape information 120.50.99, 220.50.99 is identified, it isreviewed for its accuracy and completeness. First, the collection ofplayer shape information is removed from this method 1 and furtheranalysis, if it is incomplete (e.g., contains large holes) in step120.52, 220.52. Next, in step 120.54, 220.54, the collection of playershape information is removed from this method 1 and further analyzed, ifother information about the player (e.g., player's position or level) ismissing. If the collection of player shape information is removed forany reason, including the above reasons, then the system will try andobtain this information by searching the team database, sending aninquiry to the coach, or sending an inquiry to the individual player.Once this missing information is obtained, this helmet selection and/ormanufacturing may continue. If this information cannot be obtained, thencertain protective sports helmets may not be available or the selectedprotective sports helmet may not be based on the player's shapeinformation.

Next, a body part model 120.58.99, 220.58.99 is created for the playerbased on the collected shape information 120.50.99, 220.50.99 in step120.58, 220.58. One method of creating the body part model 120.58.99,220.58.99 is using a photogrammetry based method. In particular,photogrammetry is a method that creates a model, preferably a 3D model,by electronically combining images or frames of a video. The electroniccombination of these images or frames from a video may be accomplishedin a number of different ways. For example, Sobel edge detection orCanny edge detection may be used to roughly find the edges of the objectof interest (e.g., the scanning hood 110.8.2, 210.8.2 or scanning helmet110.36.2, 210.36.2). The computerized modeling system may then removeparts of each image or frame that are known not to contain the object ofinterest. This reduces the amount of data that will need to be processedby the computerized modeling system in the following steps.Additionally, removing parts of the images or frames, which are knownnot to contain the objects of interest reduces the chance of errors inthe following steps, such as the correlating or matches of a referencepoint contained within the object of interest with the background of theimage.

While still in step 120.58, 220.58, the computerized modeling systemprocesses each image or frame of video to refine the detection of theedges or detect reference markers 110.8.2.2.2, 210.8.2.2.2. Afterrefining the detection of the edges or detecting reference markers110.8.2.2.2, 210.8.2.2.2, the computerized modeling system correlates oraligns the edges or reference markers 110.8.2.2.2, 210.8.2.2.2 in eachimage to other edges or reference markers 110.8.2.2.2, 210.8.2.2.2 inother images or frames. The computerized modeling system may use any oneof the following techniques to align the images or frames with oneanother: (i) expectation-maximization, (ii) iterative closest pointanalysis, (iii) iterative closest point variant, (iv) Procrustesalignment, (v) manifold alignment, (vi) alignment techniques discussedin Allen B, Curless B, Popovic Z. The space of human body shapes:reconstruction and parameterization from range scans. In: Proceedings ofACM SIGGRAPH 2003 or (vii) other known alignment techniques. Thisalignment informs the computerized modeling system of the position ofeach image or frame of video, which is utilized to reconstruct a bodypart model 120.58.99, 220.58.99 based on the acquired shape information.

The body part model 120.58.99, 220.58.99 may also be created by thecomputerized modeling system using the shape information that isobtained by the above described non-contact LiDAR or time-of-flightbased scanner. In this example, the computerized modeling system willapply a smoothing algorithm to the points contained within the pointcloud that was generated by the scanner. This smoothing algorithm willcreate a complete surface from the point cloud, which in turn will bethe body part model 120.58.99, 220.58.99. Further, the body part model120.58.99, 220.58.99 may be created by the computerized modeling systemusing the collection of pressure measurements that were taken by thecontact scanner. Specifically, each of the measurements will allow forthe creation of points within space. These points can then be connectedin a manner that is similar to how points of the point cloud wereconnected (e.g., using a smoothing algorithm). Like above, thecomputerized modeling system's application of the smoothing algorithmwill create a complete surface, which in turn will be the body partmodel 120.58.99, 220.58.99. Alternatively, the body part model120.58.99, 220.58.99 may be created by the computerized modeling systembased on the shape information that was gathered using any of thedevices or methods that were discussed above.

Alternatively, a combination of the above described technologies/methodsmay be utilized to generate the body part model 120.58.99, 220.58.99.For example, the body part model 120.58.99, 220.58.99 may be createdusing a photogrammetry method and additional information may be added tothe model 120.99, 220.99 based on a contact scanning method. In afurther example, the body part model 120.58.99, 220.58.99 may be createdby the computerized modeling system based on the point cloud that isgenerated by the LiDAR sensor and additional information may be added tothe body part model 120.58.99, 220.58.99 using a photogrammetrytechnique. It should also be understood that the body part model120.58.99, 220.58.99 may be analyzed, displayed, manipulated, or alteredin any format, including a non-graphical format (e.g., values containedwithin a spreadsheet) or a graphical format (e.g., 3D model in a CADprogram). Typically, the 3D body part model 120.58.99, 220.58.99 isshown by a thin shell that has an outer surface, in a wire-frame form(e.g., model in which adjacent points on a surface are connected by linesegments), or as a solid object, all of which may be used by the systemand method disclosed herein.

Once the body part model 120.58.99, 220.58.99 is created, thecomputerized modeling system determines a scaling factor. This ispossible because the size of the reference markers 110.8.2.2.2,210.8.2.2.2 or other objects (e.g., coin, ruler, etc.) within the imagesor frames are known and fixed. Thus, the computerized modeling systemdetermines the scaling factor of the model by comparing the known sizeof the reference markers 110.8.2.2.2, 210.8.2.2.2 to the size of thereference markers in the model 120.99, 220.99. Once this scaling factoris determined, the outermost surface of the body part model 120.58.99,220.58.99 closely represents the outermost surface of the player's bodypart along with the outermost surface of the scanning hood 110.8.2,210.8.2. While the thickness of the scanning hood 110.8.2, 210.8.2 istypically minimal, it may be desirable to subtract the thickness of thescanning hood 110.8.2, 210.8.2 from the body part model 120.58.99,220.58.99 after the model is properly scaled to ensure that the bodypart model 120.58.99, 220.58.99 closely represents the outermost surfaceof the player's body part. Alternatively, the thickness of the scanninghood 110.8.2, 210.8.2 may not be subtracted from the body part model120.58.99, 220.58.99.

Once the body part model 120.58.99, 220.58.99 is created and scaled instep 120.58, 220.58, anthropometric landmarks 120.60.2, 220.60.2 may beplaced on known areas of the body part model 120.58.99, 220.58.99 by thecomputerized modeling system in step 120.60, 220.60. Specifically, FIG.15 shows multiple views of an exemplary body part model 120.58.99,220.58.99, which includes a preset number of anthropometric points120.60.2, 220.60.2 are positioned thereon. These anthropometric points120.60.2, 220.60.2 typically are placed at locations that can beidentified across most body part model 120.58.99, 220.58.99. As shown inFIG. 15, the points 120.60.2, 220.60.2 are positioned on the tip of thenose, edges of the eyes, between the eyes, the forwardmost edge of thechin, edges of the lips, and other locations. It should be understoodthat a body part model 120.58.99, 220.58.99 may be a model of any bodypart of the player/helmet wearer, including a head, foot, elbow, torso,neck, and knee. The following disclosure focuses on the design andmanufacture of a protective sports helmet 1000 that is designed toreceive and protect a player's head. Thus, the body part model120.58.99, 220.58.99 discussed below in the next stages of the method isa model of the player's head or a “head model.” Nevertheless, it shouldbe understood that the following discussion involving the head model inthe multi-step method 1 is only an exemplary embodiment of the method 1for the selection and/or design of a protective helmet 1000, and thisembodiment shall not be construed as limiting.

Referring back to FIG. 12, in step 120.62, 220.62, the head model120.99, 220.99 is registered or aligned in a specific location using thecomputerized system. This is done to ensure that the head model 120.99,220.99 is in a known position to enable the comparison between theplayer's head model 120.99, 220.99 with: (i) body part models that werederived from other players, (ii) reference surfaces associated withstock energy attenuation assemblies, (iii) reference surfaces associatedwith stock helmets, or (iv) other relevant information. Specifically,this registration or alignment removes head rotations, alignment shifts,and sizing issues between the models 120.99, 220.99. This can be done ina number of ways, a few of which are discussed below. For example, onemethod of aligning the head models 120.99, 220.99 may utilize arotational based method on the placement of the anthropometric points120.60.2, 220.60.2. This method is performed by first moving the entirehead model to a new location, wherein in this new location one of theanthropometric points 120.60.2, 220.60.2 positioned at a zero. Next, tworotations are performed along Z and Y axes so that the left and righttragions lie along the X-axis. Finally, the last rotation is carried outalong the X-axis so that the left infraorbital lies on the XY-plane.This method will be repeated for each head model, helmet model, andhelmet component model to ensure that relevant data is aligned in thesame space.

An alternative method of aligning the relevant data (e.g., head models120.99, 220.99 and helmet models) may include aligning anthropometricpoints 120.60.2, 220.60.2 that are positioned on the head models 120.99,220.99 with anthropometric points that are positioned on a generic headmodel. The alignment of the anthropometric points may be accomplishedusing any of the methods that are disclosed above (e.g.,expectation-maximization, iterative closest point analysis, iterativeclosest point variant, Procrustes alignment, manifold alignment, andetc.) or methods that are known in the art. Another method of aligningthe relevant data may include determining the center of the head model120.99, 220.99 and placing the center at 0, 0, 0. It should beunderstood that one or a combination of the above methods may beutilized to align or register the head models 120.99, 220.99 with oneanother. Further, it should be understood that other alignmenttechniques that are known to one of skill in the art may also be used inaligning the head models 120.99, 220.99 with one another. Suchtechniques include the techniques disclosed in all of the papers thatare attached to U.S. Provisional Application No 62/364,629, which areincorporated into the application by reference.

After the head model 120.99, 220.99 is aligned and registered in space,the computerized modeling system may apply a smoothing algorithm to thehead model 120.58.99, 220.58.99 in step 120.64, 220.64. Specifically,the head model 120.58.99, 220.58.99 may have noise that was introducedby movement of the player's head H while the shape information wasobtained or a low resolution scanner was utilized. Exemplary smoothingalgorithms that may be applied include: (i) interpolation function, (ii)the smoothing function described within Allen B, Curless B, Popovic Z.The space of human body shapes: reconstruction and parameterization fromrange scans. In: Proceedings of ACM SIGGRAPH 2003, or (iii) othersmoothing algorithms that are known to one of skill in the art (e.g.,the other methods described within the other papers are attached to orincorporated by reference in U.S. Provisional Patent Application No.62/364,629, each of which is incorporated herein by reference).

If the system or designer determines that the head model 120.58.99,220.58.99 is too incomplete to only use a smoothing algorithm, the headmodel 120.58.99, 220.58.99 may be overlaid on a generic model in step120.66, 220.66. For example, utilizing this generic model fitting incomparison to attempting to use a smoothing algorithm is desirable whenthe head model 120.58.99, 220.58.99 is missing a large part of the crownregion of the player's head. To accomplish this generic model fitting,anthropometric landmarks 120.60.2, 220.60.2 that were placed on the headmodel 120.99, 220.99 are then aligned with the anthropometric landmarks120.60.2, 220.60.2 of the generic model using any of the alignmentmethods that are disclosed above (e.g., expectation-maximization,iterative closest point analysis, iterative closest point variant,Procrustes alignment, manifold alignment, and etc.) or methods that areknown in the art. After the head model 120.99, 220.99 and the genericmodel are aligned, the computerized modeling system creates gap fillersthat are based upon the generic model. Similar gap filling technique isdiscussed within P. Xi, C. Shu, Consistent parameterization andstatistical analysis of human head scans. The Visual Computer, 25 (9)(2009), pp. 863-871, which is incorporated herein by reference. Itshould be understood that a smoothing algorithm from step 120.60, 220.60may be utilized after gaps in the head model 120.99, 220.99 are filledin step 120.62, 220.62. Additionally, it should be understood that thehead model 120.99, 220.99 may not require smoothing or filling; thus,steps 120.64, 220.64, 120.66, 220.66 are skipped.

After the head models 120.99, 220.99 are aligned or registered in step120.66, 220.66 and the surfaces of the head models 120.99, 220.99 havebeen adjusted, surface data that is not relevant to the fitting of thehelmet or non-fitting surface 120.68.2, 220.68.2 may be removed from thehead model 120.99, 220.99 in step 120.68, 220.68. This step of removingthe non-fitting surface area 120.68.2, 220.68.2 may be accomplished in anumber of different ways. For example, an algorithm can be utilized toestimate the non-fitting surface 120.68.2, 220.68.2 and the fittingsurface 120.68.4, 220.68.4. This algorithm may be based on: (i)commercial helmet coverage standards, such as the standards set forth byNational Operating Committee on Standards for Athletic Equipment, (ii)the surface area that is covered by the scanning hood 110.8.2, 210.8.2,(iii) historical knowledge or (iv) other similar methods. FIGS. 16A-16Cshow exemplary embodiments of the fitting surface 120.68.4, 220.68.4 andthe non-fitting surface 120.68.2, 220.68.2. Once this fitting surface120.68.4, 220.68.4 is determined, then all non-fitting surfaces120.68.2, 220.68.2 may be removed from the head model 120.99, 220.99.

Alternatively, the non-fitting surfaces or irrelevant surfaces 120.68.2,220.68.2 may be removed from the head model 120.99, 220.99 using thehelmet scan. This may be accomplished by aligning the helmet scan withthe head model 120.99, 220.99 using any of the methods that aredisclosed above (e.g., expectation-maximization, iterative closest pointanalysis, iterative closest point variant, Procrustes alignment,manifold alignment, and etc.) or other methods that are known in theart. For example, the helmet scan's reference markers 110.8.2.2.2,210.8.2.2.2 that are detected through the one or more apertures110.36.2.2, 210.36.2 formed in a shell 110.36.2.3, 210.36.3 of thescanning helmet 110.36.2, 210.36.2 may be aligned with the samereference markers 110.8.2.2.2, 210.8.2.2.2 contained on the head model120.99, 220.99. Alternatively, a player's anthropometric features (e.g.,brow region, upper lip region, nose bridge or nose tip) that arecontained within both the helmet scan and the head model 120.99, 220.99may be aligned. Once these alignment methods are utilized, a visualand/or manual inspection of the alignment across multiple axes can beperformed by a human or computer software. Once the alignment of thehelmet scan and the head model are confirmed, then the non-fittingsurface 120.68.2, 220.68.2 can be removed from the head model in step120.68, 220.68.

In a further alternative, the non-fitting surfaces 120.68.2, 220.68.2may be removed from the head model 120.99, 220.99 but the anthropometriclandmarks 120.60.2, 220.60.2 may not be removed, even if they arelocated within the regions of the non-fitting surfaces 120.68.2,220.68.2. This may be desirable because these landmarks 120.60.2,220.60.2 may be used during later stages of this method 1 to ensureproper alignment between the head model 120.99, 220.99 and digitalhelmets. In even a further alternative, the non-fitting surfaces120.68.2, 220.68.2 may not be removed from the head model 120.99,220.99. These non-fitting surfaces 120.68.2, 220.68.2 might not need tobe removed because the scanning technology (e.g., contact scanner orpressure scanner) that was utilized only identifies fitting surfaces120.68.4, 220.68.4. Additionally, the designer may desire not to thesenon-fitting surfaces 120.68.2, 220.68.2 because they may aid inmanipulation or alignment of the head model 120.99, 220.99 during laterstages of this method 1.

Upon the completion of any one of the following steps 120.62, 220.62,120.64, 220.64, 120.66, 220.66, 120.68, 220.68, complete head model120.70.99, 220.70.99 are outputted in steps 120.70, 220.70. Theseoutputs: (i) form at least a portion of the player's profile 120.99,220.99 and (ii) can be uploaded to a database, local or remote, that canbe accessed by technicians who perform the next steps in selecting,designing and/or manufacturing the helmet 1000. Additionally, the systemmay combine the complete head model 120.70.99 with the complete impactmatrix/impact score 120.8.99 to create a player profile 120.99, whichincludes both impact and shape information. Similar to what has beendescribed above, this version of the player's profile 120.99, 220.99,320.99 can be uploaded to a database, local or remote, that can beaccessed by technicians who perform the next steps in selecting,designing and/or manufacturing the helmet 1000.

It should be understood that the steps described within the method ofpreparing the information 120, 220, 320 may be performed in a differentorder. For example, the removal of information that is incomplete insteps 120.4, 320.4, 120.52, 220.52 and removal of information that ismissing other relevant info 120.6, 320.6, 120.54, 220.54 may not beperformed or may be performed at any time after steps 120.2, 320.2,120.50, 220.50, respectfully. Further, it should be understood that theimpact information may not be analyzed if the process of designing andmanufacturing the helmet 1000 is focused on using only shapeinformation. Likewise, it should be understood that the shapeinformation may not be analyzed if the process of designing andmanufacturing the helmet 1000 is focused on using only impactinformation.

E. Selection of a Stock Helmet or Stock Helmet Components

After the player's profile 120.99, 220.99, 320.99 has beencreated—namely: (i) the combination of a complete head model 120.70.99and a complete impact matrix/score 120.8.99, (ii) only the complete headmodel 220.70.99, or (iii) only the complete impact matrix/score320.8.99, the player's profile 120.99, 220.99, 320.99 is compared todigital information 170.2, 270.2, 370.2 associated with stock helmets orstock helmet components to determine which stock helmet or stock helmetcomponents best fit the player's profile 120.99, 220.99, 320.99.

1. Importation of Information Associated with Stock Helmet or StockHelmet Components

Referring to FIG. 17, digital information 170.2 (e.g., digital models ofhelmets, heads, impact matrixes/scores, or other parameters) about stockhelmet or stock helmet components are imported into the system in step170.1, 270.1, 370.1, which were obtained from or derived from: (i)historical knowledge, (ii) public databases, (iii) organizational bodies(e.g., NFL, NCAA), (iv) research companies or institutions (e.g.,Virginia Tech), or (v) the process disclosed within U.S. patentapplication Ser. No. 16/543,371. In one embodiment, the method 1disclosed herein may import the complete stock helmet models 170.4,270.4, 370.4 that were created within U.S. patent application Ser. No.16/543,371. Generally, these complete stock helmet models 170.4, 270.4,370.4 were created by selecting a group of players from a plurality ofplayers and analyzing shape information and impact information,associated with the selected group, in order to generate a completestock helmet model 170.4, 270.4, 370.4. As discussed within U.S. patentapplication Ser. No. 16/543,371, the selection of a specific group ofplayers may be based upon: (i) player position, (ii) player level, or(iii) a combination of player position and level. Here, an example ofthe complete stock helmet models 170.4 is shown in FIG. 18. Inparticular, FIG. 18 shows the complete stock helmet model 170.4 andsupporting information 170.6 (e.g., shape information 170.6.2 and impactinformation 170.6.4) from which it was derived. In this exemplaryembodiment, there are four complete stock helmet models 170.4.2,170.4.4, 170.4.6, 170.4.8 that can be denoted as a small size, mediumsize, large size, and extra-large size. Likewise, there are fourcollections of shape information 170.6.2.2, 170.6.2.4, 170.6.2.6,170.6.2.8 and four collections of impact information 170.6.4.2,170.6.4.4, 170.6.4.6, 170.6.4.8. To better understand how the fourcollections of shape information 170.6.2.2, 170.6.2.4, 170.6.2.6,170.6.2.8 differ from one another, FIG. 19 compares the outer surface170.6.2.1 of these collections 170.6.2.2, 170.6.2.4, 170.6.2.6,170.6.2.8. Overall, in this exemplary embodiment of cross-sectionalviews, it can be seen that the overall circumference shown in 2-2 doesnot change as much as the elevation in the crown of the head shown in1-1 and 3-3.

In addition to the supporting information 170.6 that is described above,each complete stock helmet model 170.4, 270.4, 370.4 includes referencesurfaces 170.20, 270.20. An exemplary graphical embodiment of thesereference surfaces 170.20, 270.20 is shown in FIG. 20. One of thereference surfaces 170.20 that is shown in FIG. 20 is a minimumcertified surface (MCS) 170.20.2. This MCS 170.20.2 is defined by acollection of minimum distance values 170.20.2.2 that extend inward fromthe inner surface 170.30.2 of the helmet shell 170.30. When the completestock helmet model 170.4 is properly placed on the complete head model120.70.99, the outer surface 120.70.99.2 of the complete head model120.70.99 should not extend beyond the MCS 170.20.2. As such, if theouter surface 120.70.99.2 of the complete head model 120.70.99 extendsthrough the MCS 170.20.2, then a larger helmet shell 170.30 needs to beselected and utilized for the player. Alternatively, if the outersurface 120.70.99.2 of the complete head model 120.70.99 does not extendthrough the MCS 170.20.2, then the MCS 170.20.2 is satisfied and theselected helmet shell 170.30 can be utilized for the player. In otherwords, the MCS 170.20.2 is satisfied when the distance between the innersurface 170.30.2 of the helmet shell 170.30 and the outer surface120.70.99.2 of the player's head is greater than or equal to the minimumdistance values 170.20.2.2 for a particular shell size. It should beunderstood that satisfying the MCS 170.20.2 does not mean that thehelmet is properly sized for the player's head. For example, a helmetthat is too large for a player will not fit properly, but the MCS170.20.2 will be satisfied. Thus, the MCS 170.20.2 is used to ensurethat the player is not given too small of a helmet.

In addition to the MCS 170.20.2, the complete stock helmet model 170.4may include a maximum surface 170.20.4. This maximum surface 170.20.4 isderived from analyzing the shape information that is associated with theselected group of players and may be included within the playergroup—shape based standard and/or player group—shape+impact basedstandard. See U.S. patent application Ser. No. 16/543,371. Like the MCS170.20.2, when the complete stock helmet model 170.4 is properly alignedwith the complete head model 120.70.99, using the techniques that arediscussed above, the outer surface 120.70.99.2 of the complete headmodel 120.70.99 should not extend beyond the maximum surface 170.20.4.As such, if the outer surface 120.70.99.2 of the complete head model120.70.99 extends through or beyond the maximum surface 170.20.4, then alarger helmet shell 170.30 is typically needed. In certain embodiments,the complete head model 120.70.99 may extend beyond the maximum surface170.20.4 because the maximum surface 170.20.4 is only a suggestedreference surface that is designed to help ensure that the pressureexerted by the energy attenuation assembly 170.40 on the player's headdoes not exceed the maximum pre-impact pressure (e.g., 10 psi).Alternatively, if the outer surface 120.70.99.2 of the complete headmodel 120.70.99 does not extend through the maximum surface 170.20.4,then the maximum surface 170.20.4 is satisfied and the selected completestock helmet model 170.4 can be utilized for the player. It should beunderstood that satisfying the maximum surface 170.20.4 does not meanthat the helmet is properly sized for the player's head. For example, ahelmet that is too large for a player will not fit properly, but themaximum surface 170.20.4 will be satisfied. In a non-limiting exemplaryembodiment of the complete stock helmet model 170.4.6, the maximumsurface 170.20.4 may be inset approximately four millimeters from theinner surface of the energy attenuation assembly 170.40.

In addition to the MCS 170.20.2 and the maximum surface 170.20.4, thecomplete stock helmet model 170.4 may include a minimum surface170.20.6. This minimum surface 170.20.6 is derived from analyzing theshape information that is associated with the selected group of playersand may be included within the player group—shape based standard and/orplayer group—shape+impact based standard. See U.S. patent applicationSer. No. 16/543,371. Unlike the MCS 170.20.2, when the complete stockhelmet model 170.4 is properly aligned with the complete head model120.70.99, using the techniques that are discussed above, the outersurface 120.70.99.2 of the complete head model 120.70.99 should extendbeyond the minimum surface 170.20.6. As such, if the outer surface120.70.99.2 of the complete head model 120.70.99 does not extend throughthe minimum surface 170.20.6, then a smaller helmet shell 170.30 istypically needed. In certain embodiments, the complete head model120.70.99 may not extend beyond the minimum surface 170.20.6 because theminimum surface 170.20.6 is only a suggested reference surface that isdesigned to help ensure that the pressure exerted by the energyattenuation assembly 170.40 on the player's head is not below a minimumpre-impact pressure (e.g., 1 psi). Alternatively, if the outer surface120.70.99.2 of the complete head model 120.70.99 does extend through theminimum surface 170.20.6, then the minimum surface 170.20.6 is satisfiedand the selected complete stock helmet model 170.4 can be utilized forthe player. In a non-limiting exemplary embodiment of the complete stockhelmet model 170.4.6, the minimum surface 170.20.6 may be insetapproximately one millimeter from the inner surface of the energyattenuation assembly 170.40.

While the reference surfaces 170.20 are only shown for one completestock helmet model 170.4, it should be understood that every completestock helmet model 170.4, 270.4, 370.4 includes such reference surfaces170.20, 270.20. Additionally, it should be understood that fewerreference surfaces 170.20, 270.20 may be included in each complete stockhelmet model 170.4, 270.4, 370.4. For example, the complete stock helmetmodel 170.4, 270.4, 370.4 may only include the MCS 170.20.2, 270.20.2.Further, it should be understood that the complete stock helmet model170.4, 270.4, 370.4 may include additional reference surfaces 170.20,270.20. It should also be understood that while this example shows fourcomplete stock helmets 170.4, 270.4, 370.4, U.S. patent application Ser.No. 16/543,371 contemplates the inclusion of additional complete stockhelmets 170.4, 270.4, 370.4. For example, there may be 27 complete stockhelmets 170.4 based upon the analysis of all players, 40 complete stockhelmets 170.4 based on player position, 19 complete stock helmets 170.4based on player level, and 46 complete stock helmets 170.4 based on bothplayer position and level. Alternatively, there may be fewer than 4complete stock helmets 170.4 or there may be more than 46 complete stockhelmets 170.4.

In an alternative embodiment, the method 1 disclosed herein may importthe complete stock helmet models 270.4 that were created within U.S.patent application Ser. No. 16/543,371 based on the analysis of shapeinformation for selected groups of players. These complete stock helmetmodels 270.4 in this embodiment do not account for impact informationand thus do not include this information. Similar to the abovedisclosure, there may be 7 complete stock helmets 270.4 based upon theanalysis of all players, 18 complete stock helmets 270.4 based on playerposition, 11 complete stock helmets 270.4 based on player level, and 24complete stock helmets 270.4 based on both player position and level.Alternatively, there may be fewer than seven complete stock helmets270.4 or there may be more than 24 complete stock helmets 270.4. Inanother alternative embodiment, the method 1 disclosed herein may importthe complete stock helmet models 370.4 that were created within U.S.patent application Ser. No. 16/543,371 based on the analysis of impactinformation for selected groups of players. These complete stock helmetmodels 370.4 in this embodiment do not account for shape information andthus do not include this information. Similar to the above disclosure,there may be 14 complete stock helmets 370.4 based upon the analysis ofall players, 12 complete stock helmets 370.4 based on player position,21 complete stock helmets 370.4 based on player level, and 35 completestock helmets 370.4 based on both player position and level.Alternatively, there may be fewer than 14 complete stock helmets 370.4or there may be more than 35 complete stock helmets 370.4.

In a further embodiment, only correlations between stock helmetcomponents may be imported. For example, helmet shells may be importedwith MCS 170.20.2. 270.20.2, which may be used to inform the designerabout the maximum player head size that the helmet shell canaccommodate. Similarly, members of the energy attenuation assembly170.40, 270.40, 370.40 may only include information about which shellsthey fit into, their thickness profile, playing level (e.g., youth,varsity, NCAA, NFL) that they are optimized for and/or playing positions(e.g., lineman, quarterback, receiver, running back, etc.) that they areoptimized for. Overall, this embodiment does not include complete stockhelmet models but instead individual stock helmet components.

In another embodiment, a hybrid between the complete stock helmet model170.4, 270.4, 370.4 and the correlation between stock helmet componentsmay be utilized. For example, complete stock helmet models 170.4, 270.4,370.4 that are disclosed within U.S. patent application Ser. No.16/543,371 may be imported along with a present number of differentenergy attenuation assemblies. This embodiment simplifies the selectionof the stock helmet components and helps ensure the method 1 onlyprovides results that are desirable. For example, if the method 1 ispermitted to select each and every component based on a player'sprofile, then the method 1 may take too long to analyze all thecombinations of helmet components or suggest some undesirable matches.Additionally, this hybrid approach helps ensure the method 1 can utilizea sufficient number of combinations of helmet components to best matchthe player's profile 120.99, 220.99, 320.99.

2. Digital Selection of a Stock Helmet or Stock Helmet Components

Digital information 170.2, 270.2, 370.2 (e.g., digital models ofhelmets, heads, impact matrixes/scores, or other parameters) about thecomplete stock helmet models 170.4, 270.4, 370.4 or stock helmetcomponents are imported into the system in step 170.1, 270.1, 370.1.This imported information is compared to the player's profile 120.99,220.99, 320.99 to determine which complete stock helmet models 170.4,270.4, 370.4 or stock helmet components best fit the player's profile120.99, 220.99, 320.99 in step 170.50, 270.50, 370.50. This comparisonand selection can be performed in multiple different ways depending onthe digital information 170.2, 270.2, 370.2 that is imported into thesystem, as discussed below.

i. Selection of a Complete Stock Helmet Model from a Plurality ofComplete Stock Helmet Models

Referring to FIG. 17, the complete stock helmet models 170.4, 270.4,370.4 that best matches the player may be selected based upon: (i) theplayer's profile 120.99, which contains the player's complete head model120.70.99 and the player's complete impact matrix/score 120.8.99, (ii)the player's profile 220.99, which contains only the player's completehead model 220.70.99, or (iii) the player's profile 320.99, whichcontains only the player's complete impact matrix/score 320.8.99. Asshown in FIG. 1, once the complete stock helmet models 170.4, 270.4,370.4 or stock helmet components are chosen in steps 170, 270, 370, theparts that correspond to these models may be shipped to the player instep 199A, 299A, 399A.

1. Selection Based on the Player's Head Model and Impact Matrix/Score

Referring to FIG. 21, the process 170.60.2 of selecting the completestock helmet 170.4 that best matches the player's profile 120.99 startsby importing and confirming that the player's profile 120.99 containsthe player's complete head model 120.70.99 and the player's completeimpact matrix/score 120.8.99 in step 170.60.2.2. After this data isimported and confirmed in step 170.60.2.2, then the designer inputs apredetermined distance 170.60.2.4.2 in step 170.60.2.4, which isutilized to modify an outer surface 120.70.99.2 of the complete headmodel 120.70.99. A graphical example of this modification is shown inFIG. 24, where the outer surface 120.70.99.2 of the complete head model120.70.99 is moved inward a predetermined distance 170.60.2.4.2 to formthe inset modified surface 120.70.99.4. In other words, the designercreated the modified surface 120.70.99.2 by “insetting” or moving inwardthe outer surface 120.70.99.2 a predetermined distance 170.60.2.4.2,where this inset provides appreciable benefits, including creating aninterference fit between the player's head (i.e., outer surface120.70.99.2 of the complete head model 120.70.99) and the inner surface170.40.2 of the energy attenuation assembly 170.40. It should beunderstood that the predetermined distance 170.60.2.4.2 may be: (i) apositive value, which insets the outer surface, (ii) zero, which doesnot alter the outer surface, or (iii) a negative value, which expandsthe outer surface.

Referring back to FIG. 21, the next step in selecting the complete stockhelmet 170.4 is to compare the outer surface 120.70.99.2 of the completehead model 120.70.99 against the MCS 170.20.2 for each of the completestock helmets 170.4 that were previously created and contained withinthe database in step 170.60.2.8. See U.S. patent application Ser. No.16/543,371. As discussed above, the MCS 170.20.2 is satisfied when theouter surface 120.70.99.2 does not extend through the MCS 170.20.2. Ifthe MCS 170.20.2 that is associated with a complete stock helmet 170.4is not satisfied in step 170.60.2.8, then that complete stock helmet170.4 is removed from further analysis in step 170.60.2.10. Threegraphical examples of complete stock helmets 170.4 are shown in FIGS.25-27 and are compared against the outer surface 120.70.99.2 of thecomplete head model 120.70.99. In particular, FIG. 25 shows a graphicalimage of a large size complete stock helmet 170.4.6, while FIG. 26 showsa graphical image of a small size complete stock helmet 170.4.2 and FIG.27 shows a graphical image of a medium size complete stock helmet170.4.4. As shown in FIG. 26, the MCS 170.20.2.2 is not satisfiedbecause the outer surface 120.70.99.2.2 of the complete head model120.70.99 extends through or beyond the MCS 170.20.2.2. In other words,a small size complete stock helmet 170.4.2 is too small for the playerbased on the size of the player's head. Alternatively, if the MCS170.20.2 that is associated with a complete stock helmet 170.4 issatisfied in step 170.60.2.8, then that complete stock helmet 170.4remains available for selection in step 170.60.2.12. As shown in FIGS.25 and 27, the MCS 170.20.2.6, 170.20.2.4 is satisfied because the outersurface 120.70.99.2, 120.70.99.2 of the complete head model 120.70.99,120.70.99 does not extend through the MCS 170.20.2.6, 170.20.2.4. Inother words, the large size complete stock helmet 170.4.6 and the mediumsize complete stock helmet 170.4.4 may fit the player. This being said,additional steps will be performed to ensure that the complete stockhelmet 170.4 that best fits the player's profile 120.99 is chosen.

Next, in step 170.60.2.14, the outer surface 120.70.99.2 of the completehead model 120.70.99 is compared against the maximum surface 170.20.4for each of the complete stock helmets 170.4 that remained available forselection in step 170.60.2.12. As discussed above, the maximum surface170.20.4 is satisfied when the outer surface 120.70.99.2 does not extendthrough the maximum surface 170.20.4. If the maximum surface 170.20.4that is associated with a complete stock helmet 170.4 is not satisfiedin step 170.60.2.14, then that complete stock helmet 170.4 is removedfrom further analysis in step 170.60.2.16. Although the complete stockhelmet 170.4.2 shown in FIG. 26, was previously removed from analysis instep 170.60.2.10 due to the fact that the MCS 170.20.2.2 was notsatisfied, this complete stock helmet 170.4.2 would also be removed instep 170.60.2.16 because maximum surface 170.20.4.2 is not satisfied. Asdescribed above, the small size complete stock helmet 170.4.2 is toosmall for the player based on the size of the player's head.Alternatively, if the maximum surface 170.20.4 that is associated with acomplete stock helmet 170.4 is satisfied in step 170.60.2.14, then thatcomplete stock helmet 170.4 remains available for selection in step170.60.2.18. Graphical examples of the maximum surface 170.20.4.6,170.20.4.4 that is satisfied is shown in FIGS. 25 and 27. As discussedabove, the maximum surface 170.20.4.6, 170.20.4.4 is satisfied becausethe outer surface 120.70.99.2 of the complete head model 120.70.99 doesnot extend through or beyond the maximum surface 170.20.4.6, 170.20.4.4.Also, as described above, the large size complete stock helmet 170.4.6and the medium size complete stock helmet 170.4.4 may fit the player.This being said, additional steps will be performed to ensure that thecomplete stock helmet 170.4 that best fits the player's profile 120.99is chosen.

Next, in step 170.60.2.20, the outer surface 120.70.99.2 of the completehead model 120.70.99 is compared against the minimum surface 170.20.6for each of the complete stock helmets 170.4 that remain available forselection in step 170.60.2.18. As discussed above, the minimum surface170.20.6 is satisfied when the outer surface 120.70.99.2 extends throughor beyond the minimum surface 170.20.6. If the minimum surface 170.20.6that is associated with a complete stock helmet 170.4 is not satisfiedin step 170.60.2.20, then that complete stock helmet 170.4 is removedfrom further analysis in step 170.60.2.22. A graphical example of theminimum surface 170.20.6.6 that is not satisfied is shown in FIG. 25because the outer surface 120.70.99.2 of the complete head model120.70.99 does not extend through the minimum surface 170.20.6.6. Inother words, the large size complete stock helmet 170.4.6 is too largefor the player based on the size of the player's head. Alternatively, ifthe minimum surface 170.20.6 that is associated with a complete stockhelmet 170.4 is satisfied in step 170.60.2.20, then that complete stockhelmet 170.4 remains available for selection in step 170.60.2.24.Graphical examples of the minimum surface 170.20.6.2, 170.20.6.4 thatare satisfied are shown in FIGS. 26-27. As discussed above, the minimumsurface 170.20.6.2, 170.20.6.4 are satisfied because the outer surface120.70.99.2 of the complete head model 120.70.99 extends through theminimum surface 170.20.6.2, 170.20.6.4. In other words, complete stockhelmets 170.4.2, 170.4 are small enough to ensure that the player's headwill make at least the minimum amount of contact with the energyattenuation assembly 2000, 3000, when the player places the helmet ontheir head.

Based on the above analysis, the only graphical representation of thecomplete stock helmet models 170.4 that passes each of these tests isshown in FIG. 27. In other words, the complete stock helmet model170.4.4 shown in FIG. 27 satisfies: (i) the MCS 170.20.2.4 and themaximum surface 170.20.4.4 because outer surface 120.70.99.2 of thecomplete head model 120.70.99 does not extend through or beyond thesesurfaces 170.20.2.4, 170.20.4.4 and (ii) the minimum surface 170.20.6.4because outer surface 120.70.99.2 of the complete head model 120.70.99does extend through this surface 170.20.6.4. Because the complete stockhelmet model 170.4.4 passes each of the above tests, this complete stockhelmet model 170.4.4 will pass on to the analysis contained within FIG.22 in step 170.60.2.24.

Depending on how the complete stock helmet models 170.4 were generated,there may only be one complete stock helmet model 170.4 that fits theplayer or there may be multiple complete stock helmet models 170.4 thatfit the player. As shown in 170.60.2.26, a single complete stock helmetmodel 170.4 will be identified because the complete stock helmet models170.4 were created based upon all players. In other words, the playerswere not split-up into groups based on attributes, such as position,level, or position and level. In this situation, the system does notneed to analyze the player's impact matrix/score 120.8.99, 320.8.99because this analysis will not impact the selection of the completestock helmet model 170.4 due to the fact that the complete stock helmetmodel 170.4 was not created to differentiate between players that havedifferent impact matrixes/scores.

Alternatively, as shown in 170.60.2.28-170.60.2.32, multiple completestock helmet models 170.4 were identified because the complete stockhelmet models 170.4 were created after sorting the players based uponspecific attributes, such as position, level, or position and level. Inthis situation, the system performs step 170.60.2.34, which compares theplayer's impact matrix/score 120.8.99, 320.8.99 to the impactmatrix/scores 170.6.4 that are associated with the complete stock helmetmodels 170.4 that are still available for analysis. Based on thiscomparison and the protective sports helmet that the player selected inthe steps associated with step 50, the system recommends one of theidentified complete stock helmet models 170.4 in step 17.60.2.36. Inother words, this process compared the player's complete head model120.70.99 with different sized complete stock helmet models 170.4 todetermine the size of the complete stock helmet model 170.4 that bestfits the player. After the best fitting complete stock helmet models170.4 where identified, then the player's impact matrix/score 120.8.99was compared with the impact matrix/score of each of the best fittingcomplete stock helmet models 170.4. Based on this comparison and theplayer's protective sports helmet selections in step 50, the systemrecommended the complete stock helmet model that best matched the shapeof the player's head and impacts that the player receives while engagedin playing the sport in step 17.60.2.36.

It should be understood that the above analysis will attempt to suggesta complete stock helmet model 170.4 that was derived from: (i) onlyplayer's that play at a similar level to the player, (ii) only player'sthat play a similar position to the player, or (iii) only player's thatplay a similar position and a similar level to the player. However, itshould be understood that the above analysis may suggest complete stockhelmet models 170.4 that are derived from: (i) player's that play at alevel that is different than the player, (ii) player's that play aposition that is different than the player, or (iii) player's that playa position and at a level that is different than the player. Forexample, based on the player's profile 120.99, the system may recommendthat a player that typically plays running back at the varsity levelshould wear a helmet that is designed for wide receivers that play atthe NCAA level. Additionally, based on the player's profile 120.99, thesystem may recommend that a player that typically plays tight end at theNCAA level should wear a helmet that is designed for lineman that playat the NCAA level. Further, based on the player's profile 120.99, thesystem may recommend that a quarterback that plays at the NCAA levelshould wear a helmet that is designed for a quarterback that plays atthe varsity level. Moreover, based on the player's profile 120.99, thesystem may recommend that a wide receiver that plays at the youth levelshould wear a helmet that is designed for a wide receiver that plays atthe varsity level. Finally, based on the player's profile 120.99, thesystem may recommend that a lineman that plays at the NCAA level shouldwear a helmet that is designed for a lineman that plays at the NCAAlevel. Lastly, it should be understood that the designer may overridethe selection, if the selection appears skewed because it is not basedon enough information.

2. Selection Based on Only the Player's Head Model

This method 270.60.2 of selecting the complete stock helmet model 270.4is similar to the above process 170.60.2 of the complete stock helmetmodel 170.4. However, this method 270.60.2 is different from the abovemethod 170.60.2 because this method 270.60.2 does not perform steps170.60.2.26-170.60.2.36 due to the fact that the player profile 220.99does not contain impact matrixes/scores. As discussed above, the onlygraphical representation of the complete stock helmet models 270.4 thatpasses each of these tests is shown in FIG. 27. In other words, thecomplete stock helmet model 270.4.4 shown in FIG. 27 satisfies: (i) theMCS 270.20.2.4 and the maximum surface 270.20.4.4 because outer surface220.70.99.2 of the complete head model 220.70.99 does not extendsthrough these surfaces 270.20.2.4, 270.20.4.4 and (ii) the minimumsurface 70.20.6.4 because the outer surface 220.70.99.2 of the completehead model 220.70.99 extends through this surface 270.20.6.4. Becausethe complete stock helmet model 270.4.4 passed each of the above tests,this complete stock helmet model 270.4.4 will pass on to the analysiscontained within FIG. 23 in step 270.60.2.24.

Also, similar to the above disclosure, there may only be one completestock helmet model 270.4 that fits the player or there may be multiplecomplete stock helmet models 270.4 that fit the player. As shown in270.60.2.26, a single complete stock helmet model 270.4 will beidentified because the complete stock helmet models 170.4 were createdbased upon all players. In this situation, the designer does not need toanalyze or reference the protective sports helmet that the playerselected in connection with step 50 because there is only one completestock helmet model 170.4 that is available for selection. Alternatively,as shown in 270.60.2.28-270.60.2.28.32, multiple complete stock helmetmodels 270.4 will be identified because the complete stock helmet models270.4 were created after sorting the player's based upon position,level, or position and level. Thus, in this situation, the designeranalyzes the protective sports helmet that the player selected inconnection with step 50 and recommends the complete stock helmet model270.4 based on that selection in steps 270.60.2.34-270.60.2.40. Forexample, the designer will select the complete stock helmet model 270.4that best matches the player's head model 220.70.99 and then thedesigner may select a quarterback varsity helmet, if the player picked aposition and level specific helmet in step 50.78. Alternatively, thedesigner may select the complete stock helmet model 270.4 that bestmatches the player's head model 220.70.99 and then the designer mayselect a youth helmet, if the player picked a level specific helmet instep 50.76. It should be understood that a position and level specificcomplete stock helmet model 270.4 may not be available based on the sizeof the player's head. In this situation, the system will provide thedesigner with the closest available options that provide the best fitfor the player even if they are not within the selected position orlevel.

3. Selection Based on Only the Player's Impact Matrix/Score

In contrast to the above methods 170.60.2, 270.60.2, the complete stockhelmet model 370.4 may be selected by considering how the complete stockhelmet model 370.4 fits but prioritizing the match between the player'simpact matrix/score 320.8.99 over the fit in the process described in370.60.2. The first set in this process is receiving basic headmeasurements about the player. Typically, these head measurements aretaken with measuring tape and are used to roughly determine (e.g, +/−¼inch) the circumference of the player's head. These rough headmeasurements allow the system to select a helmet shell and energyattenuation assemblies that are designed to fit within that helmetshell. The player's impact matrix/score 320.8.99 is then comparedagainst the impact matrix/score that is associated with each energyattenuation assembly 370.40. Based on this comparison, the systemrecommends a complete stock helmet model 370.4 that fits the player'shead but prioritizes the player's impact matrix/score 320.8.99. Forexample, the system might recommend a helmet that is slightly largerthan would have been recommended in the methods that are described abovebecause the slightly larger shell can accommodate an energy attenuationassembly 370.40 that better matches the player's impact matrix/score320.8.99. Alternatively, the system might recommend a helmet that isslightly smaller (e.g., may place the outer surface of the player's headthrough the maximum surface but not beyond the MCS) than would have beenrecommended in the methods that are described above because the slightlysmaller shell can accommodate an energy attenuation assembly 370.40 thatbetter matches the player's impact matrix/score 320.8.99.

Upon the completion of at least one of the above methods of selecting acomplete stock helmet model 170.4, 270.4, 370.4, the physical componentsthat are associated with the complete stock helmet model 170.4, 270.4,370.4 can be identified and shipped to the player in step 199B, 299B,399B. Alternatively, the complete stock helmet model 170.4, 270.4, 370.4can be used below in connection with developing a custom energyattenuation assembly.

ii. Selection of a Combination of Stock Helmet Components from aPlurality of Combinations of Stock Helmet Components

In contrast to the above methods 170.60.2, 270.60.2, 370.60.2 ofselecting a complete stock helmet model 170.4, 270.4, 370.4, thefollowing method discloses selecting individual stock helmet componentsthat best match the player's profile 120.99, 220.99, 320.99. This method170.70.2, 270.70.2, 370.70.2 may be beneficial because it provides thedesigner with additional combinations of helmet shells and energyattenuation assemblies that may not have been available as completestock helmet models 170.4, 270.4, 370.4. However, these combinationshave not been specifically designed based upon a selected group ofplayers and thus the combinations do not include specific data about theminimum surface, the maximum surface, or the impact matrixes/scores.Nevertheless, these helmet components include other information (e.g.,thickness, compression and deflection (CD) curves, etc.) that canprovide the designer with suggestions about the functionality of thehelmet components.

Referring to FIG. 28, the first step in this process 170.70.2, 270.70.2,370.70.2 is the selection of a helmet shell from the plurality of helmetshells in step 170.70.2.2, 270.70.2.2, 370.70.2.2. If the complete headmodel 120.70.99, 220.70.99 is available, then this model 120.70.99,220.70.99 can be used to select the helmet shell. In particular, the MCS170.20.2, 270.20.2 for a first helmet shell can be compared against thecomplete head model 120.70.99, 220.70.99 in step 170.70.2.2.2,270.70.2.2.2. If the MCS 170.20.2, 270.20.2 is satisfied, then a smallerhelmet shell size is chosen in step 170.70.2.2.4, 270.70.2.2.4. Thisprocess starts over again with this smaller helmet shell and willcontinue until the MCS is not satisfied. Once the MCS is not satisfied,then a larger helmet size is chosen in step 170.70.2.2.6, 270.70.2.2.6.The MCS 170.20.2, 270.20.2 that is associated with this larger helmetshell is then compared with the complete head model 120.70.99,220.70.99. If the MCS 170.20.2, 270.20.2 is satisfied, then the helmetshell is selected in step 170.70.2.2.8, 270.70.2.2.8. Alternatively, ifthe MCS 170.20.2, 270.20.2 is not satisfied for this larger helmetshell, then the above process is repeated until the MCS 170.20.2,270.20.2 is satisfied. This process helps ensure that the smallest sizehelmet shell is chosen that fits the player (e.g., the player's headdoes not extend through or beyond the MCS 170.20.2, 270.20.2).Alternatively, if the complete head model 120.70.99, 220.70.99 is notavailable (e.g., a player profile 320.99 that does not contain thisinformation), then the rough measurements should be taken using the tapemeasure and those measurements should be utilized to choose the shellsize in step 370.70.2.2.2.

After the helmet shell size has been chosen in step 170.70.2.2,270.70.2.2, 370.2.2, then the energy attenuation assembly 170.40,270.40, 370.40 is selected from the plurality of energy attenuationassemblies in step 170.70.2.4, 270.70.2.4, 370.70.2.4. First, all energyattenuation members that fit within that helmet shell should beidentified in step 170.70.2.4.2, 270.70.2.4.2, 370.70.2.4.2. Next, thethicknesses of the energy attenuation member are chosen by aligning theinner surface of the energy attenuation members with the inset modifiedsurface 120.70.99.4, 220.70.99.4 in step 170.70.2.4.4, 270.70.2.4.4,370.70.2.4.4. Aligning these surfaces will help ensure that the energyattenuation members will be slightly compressed, prior to the playerreceiving an impact. This compression of the energy attenuation membersprior to the player receiving an impact or pre-compression causespressure to be exerted on the player's head when the helmet is worn bythe player. In other words, an interference fit is formed between theenergy attenuation assembly 2000, 3000 and the player's head, when thehelmet is worn by the player. This interference fit helps ensure thatthe helmet remains in place during play. Otherwise, without thisinterference fit, the helmet would not provide the desired fit (e.g., itwould feel loose or uncomfortable on the player's head). Generally, thepressure exerted on the player's head by the energy attenuation assembly2000, 3000 to create this interference fit should be between 1 psi and10 psi.

Once the thickness of the energy attenuation members is selected in step170.70.2.4.4, 270.70.2.4.4, 370.70.2.4.4, the next step in this processis to select the performance type of the energy attenuation members instep 170.70.2.4.6, 270.70.2.4.6, 370.70.2.4.6. Selecting the performancetype of the energy attenuation members may be based upon the player'slevel, player's position, player's position and level, or based upon theplayer's impact matrix/score. Hypothetically, it may be desirable toselect an energy attenuation member that has a higher CD for a playerthat experiences high velocity impacts. This may be desirable becausethe higher CD energy attenuation member can absorb more energy before itbottoms-out. Alternatively, it may be desirable to have an energyattenuation member that has a lower CD for a player that experiencesnumerous low velocity impacts. After step 170.70.2.4.4, 270.70.2.4.4,370.70.2.4.4 is completed, the physical components that are associatedwith the selected stock helmet components can be identified and shippedto the player in step 199A, 299A, 399A. Alternatively, the selectedstock helmet components can be used below in connection with developinga custom energy attenuation assembly.

iii. Selection of a Components that are Associated with a Complete StockHelmet

In a further alternative embodiment, the above methods may be combinedwhere the designer first selects a complete stock helmet 170.4, 270.4,370.4 from the plurality of stock helmets 170.4, 270.4, 370.4 that bestfits the player's head model 120.70.99 in step 170.80, 270.80, 370.80.After the selection of the complete stock helmet 170.4, 270.4, 370.4,the designer then may be provided with a number of stock helmetcomponents (e.g., energy attenuation members) that function within theselected complete stock helmet and provide slightly differentproperties. The designer can then select the stock helmet componentsthat best fit the player's profile 120.99, 220.99, 320.99. Upon thecompletion of this step, the physical components that are associatedwith the selected stock helmet components can be identified and shippedto the player in step 199A, 299A, 399A. Alternatively, the selectedstock helmet components can be used below in connection with developinga custom energy attenuation assembly. It should be understood that theabove described methods of selecting a complete stock helmet model170.4, 270.4, 370.4 and stock helmet components are merely exemplary andas such can be combined or performed in a different order. Additionally,steps in the above methods may be omitted or additional steps may beadded.

F. Generation of Custom Energy Attenuation Assembly

1. Custom Shaped Energy Attenuation Assembly

A custom shaped (CS) energy attenuation assembly 3000 that best matchesa player's head model 120.70.99, 220.70.99 can be created by: (i)modifying the selected complete stock helmet model 170.4, 370.4 or theselected stock helmet components, (ii) developing it from a selectedhelmet shell, or (iii) developing it from a fitting helmet. A CS energyattenuation assembly 3000 may be desirable because an optimized fit canimprove the management of impact energies (e.g., both linear androtational energies). Discussed below are multiple methods of creating aCS helmet model 280.50.

A) Custom Shaped Energy Attenuation Assembly Created from the SelectedStock Helmet or Stock Helmet Components

As described above in connection with step 170.50, 270.50, the selectedcomplete stock helmet model 170.4, 270.4 or the selected stock helmetcomponents is the stock helmet model 170.4, 370.4 or the selected stockhelmet components that best match the player's profile 120.99, 20.99.Depending on the player's selection in step 50 and the above analysis,the selected stock helmet model 170.4, 370.4 or the selected stockhelmet components may be derived from: (i) all players, (ii) onlyplayer's that play at a similar level to the player, (iii) only player'sthat play a similar position to the player, or (iv) only player's thatplay a similar position and a similar level to the player. Thus, in somesituations, the below analysis may be performed on a complete stockhelmet model 170.4, 370.4 or stock helmet components that have alreadybeen optimized for players that have attributes that are similar to theplayer. In these situations, the number of changes that are made by thebelow analysis may be reduced. In other situations, the selected stockhelmet model 170.4, 370.4 or the selected stock helmet components maynot have been optimized for players that have attributes that aresimilar to the player.

The formation of the CS energy attenuation assembly 3000 starts bygenerating a CS helmet model 280.50 of the CS energy attenuationassembly 3000 in connection with 180.10, 280.10. Referring to FIG. 29,the first step in creating the CS helmet model 280.50 is the importationof the digital files associated with the selected complete stock helmetmodels 170.4, 270.4 or the selected stock helmet components from steps170.60, 270.60, 170.70, 270.70, 170.80, 270.80 in step 180.10.2,280.10.2. Next, the player's complete head model 120.70.99, 220.70.99 isimported and aligned, using any of the methods that are described above,with the imported digital files associated with the selected completestock helmet models 170.4, 270.4 or the selected stock helmet componentsin step 180.10.4, 280.10.4. An exemplary graphical representation ofthis is shown in FIG. 30.

Once the files have been imported and aligned, the inner surface170.40.2, 270.40.2 of the energy attenuation assembly 170.40, 270.40 ismodified to match the modified surface 120.70.99.4, 220.70.99.4 of theplayer's head model 120.70.99, 220.70.99 in step 180.10.6, 280.10.6. Inother words, the topography of the front wall or inner surface 170.40.2,270.40.2 of the energy attenuation assembly 170.40, 270.40 substantiallymatches the modified surface 120.70.99.4, 220.70.99.4 of the player'shead model 120.70.99, 220.70.99. The inner surface 170.40.2, 270.40.2 ofthe energy attenuation assembly 170.40, 270.40 is not aligned with theouter surface 120.70.99.2, 220.70.99.2 of the player's head/completehead model 170.99, 270.99 because this would not create an interferencefit between the player's head and the energy attenuation assembly 3000,when the helmet 1000 was worn by the player. A graphical representationof aligning these surfaces is shown in FIG. 31.

Once the inner surface 170.40.2, 270.40.2 of the energy attenuationassembly 170.40, 270.40 is modified to match the modified surface120.70.99.4, 220.70.99.4 of the player's complete head model 120.70.99,220.70.99 in step 180.10.6, 280.10.6, the system checks to ensure thatthe changes to the selected complete stock helmet model 170.99, 270.99or selected stock helmet components have not negatively affected theperformance of the selected complete stock helmet model 170.99, 270.99or selected stock helmet components in step 180.10.8, 280.10.8.Typically, the above modification to the energy attenuation assembly170.40, 270.40 only require modifying the fitting region of the energyattenuation assembly 170.40, 270.40. Thus, these modifications typicallydo not impact the energy attenuation region of the energy attenuationassembly 170.40, 270.40 and therefore do not make significantalterations to the performance of the helmet. However, if the fittingregion is increased over a predefined distance (e.g., the player's headis significantly smaller than the selected helmet model/components) orthe energy attenuation region is altered (e.g., the player's head issignificantly larger than the selected helmet model/components), thenthe performance of the energy attenuation assembly 170.40, 270.40 may beimpacted. To determine if this impact is a negative impact, the CShelmet model 280.50 is tested using the digital testing methods (e.g.,dynamic FE testing) that are described in greater detail below in step180.10.8, 280.10.8. If the changes or modifications to the energyattenuation assembly 170.40, 270.40 did negatively impact theperformance of the helmet, then the mechanical properties of theselected complete stock helmet model or helmet components are altered instep 180.10.10, 280.10.10. An example of how these mechanical propertiesmay be altered is discussed below in connection with the creation of theCP energy attenuation assembly. Alternatively, if the changes ormodifications to the energy attenuation assembly 170.40, 270.40 did notnegatively impact the performance of the helmet, then the CS helmetmodel 280.50 is outputted in step 180.10.12, 280.10.12.

B) Custom Shaped Energy Attenuation Assembly Created from a Helmet Shell

Instead of modifying a pre-selected energy attenuation assembly, asdiscussed above, to form the CS helmet model 280.50, the CS helmet model280.50 may be developed from scratch. In this embodiment, this processis to select the size of a helmet shell from a plurality of sizes instep 180.15. Referring to FIG. 32, the MCS 170.20.2, 270.20.2 for afirst helmet shell can be compared against this complete head model120.70.99, 220.70.99 in step 180.15.2, 280.15.2. If the MCS 170.20.2,270.20.2 is satisfied, then a smaller helmet shell size is chosen instep 180.15.4, 280.15.4. This process starts over again with thissmaller helmet shell and will continue until the MCS is not satisfied.Once the MCS is not satisfied, then a larger helmet size is chosen instep 180.15.4, 280.15.4. The MCS 170.20.2, 270.20.2 that is associatedwith this larger helmet shell is then compared with the complete headmodel 120.70.99, 220.70.99. If the MCS 170.20.2, 270.20.2 is satisfied,then the helmet shell 180.15.8.99, 280.15.8.99, is selected in step180.15.8, 280.15.8. Alternatively, if the MCS 170.20.2, 270.20.2 is notsatisfied for this larger helmet shell, then the above process isrepeated until the MCS 170.20.2, 270.20.2 is satisfied. This processhelps ensure that the smallest size helmet shell is chosen that fits theplayer (e.g., the player's head does not extend through or beyond theMCS 170.20.2, 270.20.2).

Next, the selected helmet shell 180.15.8.99, 280.15.8.99 is comparedagainst the complete head model 120.70.99, 220.70.99. Based on thiscomparison, a solid is generated that extends between the modifiedsurface 120.70.99.4, 220.70.99.4 of the player's head model 120.70.99,220.70.99 and the inner surface 170.30.2 of the helmet shell 170.30 instep 180.15.10, 280.15.10. An energy attenuation template is thenapplied to the solid in step 180.15.12, 280.15.12. In this step180.15.12, 280.15.12, the application of the energy attenuation templateforms an arrangement of sidewalls. Specifically, these sidewalls extendbetween the modified surface 120.70.99.4, 220.70.99.4 of the player'shead model 120.70.99, 220.70.99 and the inner surface 170.30.2 of thehelmet shell 170.30. In other words, the side walls extend in the Zdirection and away from the outer surface of the player's head model120.70.99, 220.70.99. In the embodiments shown herein, the sidewallsthat form the arrangement of sidewalls are positioned at various anglesto one another, which aids in how the energy attenuation membersinteract with one another.

After the sidewall arrangement is defined in 180.15.12, 280.15.12,fillets are applied to edges of the sidewalls that is positionedadjacent to the complete head model 120.70.99, 220.70.99 in step180.15.14, 280.15.14. These fillets form the shoulders 170.40.20,270.40.20 of the energy attenuation members 170.40. A graphicalrepresentation of the application of these fillets is shown in FIG. 33.Specifically, in FIG. 33, the image shown on the left side of the pageis the result from step 180.15.10, 280.15.12, which includes anarrangement of side walls 180.15.10.2, 280.15.10.2, a front wall180.15.10.4, 280.15.10.4 that matches the modified surface 120.70.99.4,220.70.99.4 of the player's head model 120.70.99, 220.70.99, and rearwall 180.15.10.6, 280.15.10.6 that matches the inner surface 170.30.2 ofthe helmet shell 170.30. The image on the right side of the page is theresults from step 180.15.12, 280.15.12, wherein the edges 180.15.10.8,180.15.10.8 of the side walls 180.15.10.2, 280.15.10.2 that ispositioned adjacent to the complete head model 120.70.99, 220.70.99 arerounded. The creation of these shoulders 170.40.20, 270.40.20 isdesirable because it removes hard edges from the energy attenuationassembly 170.40 that may interact with the player's head, whichincreases the comfort of the helmet.

The CS helmet model 280.50 is finalized by providing the desired energyattenuation specification for each energy attenuation member within theenergy attenuation assembly 170.40 in step 180.15.16, 280.15.16. Theseperformance specifications may include, but is not limited to, (i) forceabsorption or load-compression curve/measurement, (ii) a compressiondeflection curve/measurement, (iii) a compression curve/measurement,(iv) a tensile strength curve/measurement, and/or (v) elongationcurve/measurement. To create one or more of these performancespecifications, the designer may collect data using methods ortechniques that include, but are not limited to: (i) historicalknowledge, (ii) data collected by placing sensors in a headform andtesting the helmet using: (A) a linear impactor, (B) a drop tester, (C)a pendulum tester, or (D) other similar types of helmet testingapparatuses, (iii) data collected by placing sensors between theheadform and the energy attenuation assembly and testing the helmetusing the above apparatuses, (iv) data collected by placing sensorsbetween the energy attenuation assembly and the helmet shell and testingthe helmet using the above apparatuses, (v) data collected by placingsensors on the external surface of the shell and testing the helmetusing the above apparatuses, (vi) helmet standards (e.g., NOCSAE), (vii)data collected from software programs using mathematical models (e.g.,finite element analysis, neural networks, or etc.) of the helmet,faceguard, and/or energy attenuation assembly, (viii) HIE data collectedby the proprietary technologies owned by the assignee of the presentApplication, which includes the systems disclosed in U.S. patentapplication Ser. No. 13/603,319 and U.S. Pat. Nos. 6,826,509, 7,526,389,8,797,165 and 8,548,768, (ix) data collected using ASTM D3574 testingprotocols, including but not limited to, Tests B1, C, E, F, X6, 13, M,(x) data collected using ISO 3386 testing protocol, (xi) data collectedusing ISO 2439 testing protocol, (xii) data collected using ISO 1798testing protocol, (xiii) data collected using ISO 8067 testing protocol,(xiv) data collected using ASTM D638 testing protocol, (xv) datacollected using ISO 37 testing protocol, (vi) data collected using ASTMD395 testing protocol, or (xvii) other similar techniques that can beused to gather data about the mechanical response of a material. Oncethe CS helmet model 280.50 is finalized, it can be outputted for use inthe next steps in designing and manufacturing the helmet 1000.

C) Custom Shaped Energy Attenuation Assembly Created from a FittingHelmet Model

In an alternative embodiment, the CS helmet model 280.50 may bedeveloped from a fitting helmet model. Specifically, the fitting helmetmodel is a standard helmet that includes an energy attenuation assemblythat has the arrangement of side walls 180.15.10.2, 280.15.10.2 and rearwall 180.15.10.6, 280.15.10.6 that matches the inner surface 170.30.2 ofthe helmet shell 170.30. The front wall of the energy attenuationassembly is designed to extend past any reasonable position and may eventhrough a portion of the helmet shell. In other words, the entire innercavity of the helmet is occupied by the energy attenuation assembly. Thereason for this configuration is discussed in greater detail below. Thefirst step in this alternative embodiment is to select a helmet shellthat fits the player. This may be done in the same manner as describedabove in connection with FIG. 32.

Once the helmet shell is selected, the player's head model 120.70.99,220.70.99 is then placed within this cavity and aligned with theselected helmet shell 180.15.8.99, 280.15.8.99 using the above describedtechniques. The system then determines the intersection between themodified surface 120.70.99.4, 220.70.99.4 of the player's head model120.70.99, 220.70.99 and the energy attenuation members. Thisintersecting surface becomes the front wall 180.15.10.4, 280.15.10.4 ofthe energy attenuation assembly that matches the modified surface120.70.99.4, 220.70.99.4 of the player's head model 120.70.99,220.70.99. In other words, the topography of the front wall or innersurface of the energy attenuation assembly substantially matches themodified surface 120.70.99.4, 220.70.99.4 of the player's head model120.70.99, 220.70.99.

After the inner surface of the energy attenuation assembly isdetermined, fillets are applied to edges of the sidewalls that ispositioned adjacent to the complete head model 120.70.99, 220.70.99. Asdiscussed above in connection with FIG. 33, these fillets form theshoulders 170.40.20, 270.40.20 of the energy attenuation members 170.40.The CS helmet model 280.50 is then finalized by providing the desiredenergy attenuation specification from the fitting helmet model. Itshould be understood that these energy attenuation specifications mayhave been derived from any of the techniques disclosed herein.

2. Custom Performance Energy Attenuation Assembly

A custom performance (CP) energy attenuation assembly that takes intoaccount the player's impact matrix/score 320.8.99 can be created by: (i)modifying the selected complete stock helmet model 170.4, 370.4 or theselected stock helmet components or (ii) generating it from scratch. ACP energy attenuation assembly may be desirable because it can provideimproved impact energy (e.g., both linear and rotational energies)management. As described in greater detail below, the CP energyattenuation assembly may be designed and developed using variousdifferent methodologies, such as: (i) a response surface methodology180.28.2, 380.28.2, (ii) a brute force methodology 180.28.4, 380.28.2,(iii) hybrid methodology 180.28.6, 380.28.6, or (iv) other optimizationmethodology.

A) Custom Performance Energy Attenuation Assembly Created from theSelected Stock Helmet or Stock Helmet Components

As described above in connection with step 170.50, 370.50, the selectedcomplete stock helmet model 170.4, 370.4 or the selected stock helmetcomponents is the stock helmet model 170.4, 370.4 or the selected stockhelmet components that best match the player's profile 120.99, 20.99.Depending on the player's selection in step 50 and the above analysis,the selected stock helmet model 170.4, 370.4 or the selected stockhelmet components may be derived from: (i) all players, (ii) onlyplayer's that play at a similar level to the player, (iii) only player'sthat play a similar position to the player, or (iv) only player's thatplay a similar position and a similar level to the player. Thus, in somesituations, the below analysis may be performed on a complete stockhelmet model 170.4, 370.4 or stock helmet components that have alreadybeen optimized for players that have attributes that are similar to theplayer. In these situations, the number of changes that are made by thebelow analysis may be reduced. In other situations, the selected stockhelmet model 170.4, 370.4 or the selected stock helmet components maynot have been optimized for players that have attributes that aresimilar to the player.

1) Response Surface Methodology

Now referring to FIGS. 34A-B, the first step in creating this CP helmetmodel 180.28.99, 380.28.99 using a response surface methodology180.28.2, 380.28.2 is to determine an energy attenuation layer testingprotocol 180.28.2.1.99, 380.28.2.1.99 in step 180.28.2.1, 380.28.2.1. Todevelop the energy attenuation layer testing protocol 180.28.2.1.99,380.28.2.1.99, the designer may import various testing protocols, suchas: (i) the NFL Linear Impactor Helmet Test Protocol, which was authoredby James Funk, Jeff Crandall, Michael Wonnacott, and Chris Withnall andpublished on Feb. 1, 2017, which is incorporated herein by reference,(ii) the Adult Football STAR Methodology, which was authored by AbigailTyson and Steven Rowson and published on Mar. 30, 2018, which isincorporated herein by reference, (iii) historical knowledge, or (iv) acombination of each of these test protocols.

After importing these protocols, the designer may then compare theprotocols to the player's profile 120.99, 320.99 to ensure that theenergy attenuation layer testing protocol 180.28.2.1.99, 380.28.2.1.99properly accounts for the player's impact history, playing style,medical history, etc. If the protocol is different from the player'sprofile 120.99, 320.99, then the designer may alter the protocol tobetter match the player's profile 120.99, 320.99. For example, VirginiaTech assumes that a player will experience 83 impacts that are at 3.0m/s condition, 18 impacts that are at 4.6 m/s, and 4 impacts that are at6.1 m/s during a season. The impacts are then evenly weighted (e.g.,25%) based on the impact location (e.g., front, front boss, side, back).Unlike these assumed impacts, the player profile 120.99, 320.99 mayinclude: (i) 53 impacts that are at 3.0 m/s condition, 35 impacts thatare at 4.6 m/s, and 17 impacts that are at 6.1 m/s during a season.Accordingly, the designer will alter the testing protocol by alteringthe weights given to each location (e.g., 32% for the back, 23% for theside, 26% for the front, and 19% for the front boss). By taking theplayer's profile 120.99, 320.99 into account when developing180.28.2.1.99, 380.28.2.1.99, the performance of the energy attenuationassembly will be tailored or bespoke to the player. It should beunderstood that this same process of developing the energy attenuationlayer testing protocol 180.28.2.1.99, 380.28.2.1.99 will be used inconnection with the other methods of developing a CP energy attenuationassembly, such as brute force methodology 180.28.4, 380.28.2, hybridmethodology 180.28.6, 380.28.6, or other types of optimizationmethodology.

The next steps are designed to test the selected complete stock helmetmodel 170.4, 370.4 or the selected stock helmet components with theircurrent configuration along with variations of these components todetermine the optimal configuration of the energy attenuation assemblyin light of the player's profile 120.99, 320.99. The first step in thistest is to extract the dependent variables in step 180.28.2.4.4,380.28.2.4.4 from the selected complete stock helmet model 170.4, 370.4and the headform that is associated with the selected complete stockhelmet model 170.4, 370.4. Next, the designer determines a range for theindependent variables 180.28.2.4.2.99, 380.28.2.4.2.99 (see FIG. 35)based upon the selected complete stock helmet model 170.4, 370.4 in step180.28.2.4.2, 380.28.2.4.2. One exemplary way of determining theseranges is by adding and subtracting 25% to the values contained withinthe selected complete stock helmet model 170.4, 370.4. It should beunderstood that other ways of determining these ranges are contemplatedby this disclosure, including utilizing historical knowledge. An exampleof the ranges that may be used in connection with the independentvariables is shown in FIG. 35.

Next, a Plackett-Burman design to select the values for the independentvariables in step 180.28.2.4.6, 380.28.2.4.6. These values will bespaced across the entire range. Next, rough testing helmets180.28.2.4.6.99, 380.28.2.4.6.99 are created based upon: (i) digitalheadform prototypes associated with the selected complete stock helmetmodel 170.4, 370.4, (ii) complete stock helmet model 170.4, 370.4, and(iii) the independent variables determined in step 180.28.2.4.2,380.28.2.4.2. It should be understood that the rough testing helmets180.28.2.4.6.99, 380.28.2.4.6.99 may be created in the form of a finiteelement model or any other digital model that contains mechanicalproperties and shape information. It should also be understood that whenan independent variable is altered from the value that is containedwithin the complete stock helmet model 170.4, 370.4, this change maycause a ripple effect that requires the alteration of other aspects ofthe rough testing helmets 180.28.2.4.6.99, 380.28.2.4.6.99. For example,if the compression ratio of the side member is changed, then maximumsurface 170.20.4, 270.20.4 may be altered to ensure that the pressureexerted on the head of the player is not too great (e.g., greater than10 psi). These rough testing helmets 180.28.2.4.6.99, 380.28.2.4.6.99are then subjected to the energy attenuation layer testing protocol180.28.2.1.99, 380.28.2.1.99, wherein the following values are recordedfor each test within the energy attenuation layer testing protocol180.28.2.1.99, 380.28.2.1.99: (i) peak linear acceleration, (ii) peakrotational acceleration, (iii) peak HITsp, and (iv) if the energyattenuation assembly bottomed out (e.g., could not absorb any additionalforce) or if the energy attenuation assembly did not bottom out, thenthe distance that the energy attenuation assembly before it would bottomout in step 180.28.2.4.10, 380.28.2.4.10. It should be understood thatone of the rough testing helmets 180.28.2.4.6.99, 380.28.2.4.6.99 willbe directly based upon the selected complete stock helmet model 170.4,370.4.

Next, the most significant independent variables are determined in step180.28.2.4.12, 380.28.2.4.12 based upon applying the energy attenuationlayer testing protocol 180.28.2.1.99, 280.28.2.1.99 in connection witheach rough testing helmet 180.28.2.4.6.99, 380.28.2.4.6.99. Once themost significant independent variables are determined, then a refinedexperimental design can be undertaken in step 180.28.2.4.14,380.28.2.4.14. Examples of more refined designs include: (i) FullFactorial Design, (ii) Box-Behnken Design, (iii) Central CompositeDesign, or (iv) a Doehlert Matrix Design. Next, refined testing helmets180.28.2.4.14.99, 380.28.2.4.14.99 are created based upon: (i) digitalheadform prototypes associated with the selected complete stock helmetmodel 170.4, 370.4, (ii) selected complete stock helmet model 170.4,370.4, and (iii) the independent variables determined in step180.28.2.4.12, 380.28.2.4.12. It should be understood that the refinedtesting helmets 180.28.2.4.14.99, 380.28.2.4.14.99 may be created in theform of a finite element model or any other digital model that containsmechanical properties and shape information. Also, like above, it shouldalso be understood that when an independent variable is altered from thevalue that is contained within the selected complete stock helmet model170.4, 370.4, this change may cause a ripple effect that requires thealteration of other aspects of the refined testing helmets180.28.2.4.14.99, 380.28.2.4.14.99. These refined testing helmets180.28.2.4.14.99, 380.28.2.4.14.99 are then subjected to the energyattenuation layer testing protocol 180.28.2.1.99, 380.28.2.1.99, whereinthe following values are recorded for each test within the energyattenuation layer testing protocol 180.8.2.1.99, 380.28.2.1.99: (i) peaklinear acceleration, (ii) peak rotational acceleration, (iii) peakHITsp, and (iv) if the energy attenuation assembly bottomed out (e.g.,could not absorb any additional force) or if the energy attenuationassembly did not bottom out, then the distance that the energyattenuation assembly before it would bottom out in step 180.28.2.4.18,280.28.2.4.18.

The data from testing the refined testing helmets 180.28.2.4.14.99,380.28.2.4.14.99 are fitted using mathematical functions, such aspolynomial function or an advanced surface fitting function (e.g.,Kigring, or radial basis function, or a combination of advanced surfacefitting functions). Exemplary fitted surfaces 180.28.2.4.20.99,380.28.2.4.20.99 are shown in FIG. 36 for a few different refinedtesting helmets. After a surface is determined for each refined testinghelmet 180.28.2.4.14.99, 380.28.2.4.14.99 in step 180.28.2.6,380.28.2.6, over a surface 180.28.2.4.20.99, 380.28.2.4.20.99 overlaidupon one another in step 180.28.2.8, 380.28.2.8. Overlaying thesesurfaces 180.28.2.4.20.99, 380.28.2.4.20.99 will allow the designer toidentify the optimized region 180.28.2.4.20.99.2, 380.28.2.4.20.99.2 bylocating where maximum values associated with each surface overlap oneanother in step 180.28.2.10, 380.28.2.10. If the maximum values do notoverlap one another, then the designer can determine an average betweenthese maximum values or may use historical knowledge in combination withthe maximum values to select an optimized region. Once the optimizedregion is selected, then the designer can determine the independentvalues that are associated with this region, which can be combined tocreate response surface testing helmets 180.28.4.12.99, 380.28.4.12.99.

Once the independent values have been derived from the optimized region180.28.2.4.20.99.2, 380.28.2.4.20.99.2, then the designer needs toverify that the response surface testing helmet 180.28.4.12.99,380.28.4.12.99 meets all helmet standard(s) (e.g., playergroup—shape+impact based helmet standard, NOCSAE, and etc.). Once it hasbeen verified that the response surface testing helmet 180.28.4.12.99,380.28.4.12.99 meets all helmet standard(s), the response surfacetesting helmet 180.28.4.12.99, 380.28.4.12.99 may undergo a visualinspection to ensure that it meets all manufacturing, marketing, andsales requirements. If the response surface testing helmet180.28.4.12.99, 380.28.4.12.99 does not meet any of these requirements,then the response surface testing helmet 180.28.4.12.99, 380.28.4.12.99may be altered to meet these requirements. Once the response surfacetesting helmet 180.28.4.12.99, 380.28.4.12.99 meets these requirements,then this response surface testing helmet 180.28.4.12.99, 380.28.4.12.99is added to a collection of response surface testing helmets180.28.4.12.99, 380.28.4.12.99, which will be compared against oneanother in the following steps.

Each of the above steps may optionally then be repeated for each methodof manufacturing (e.g., foam, Precision-Fit, and Additive Manufacturing)in step 180.28.2.14, 380.28.2.14. These methods must be performedindividually because each manufacturing method has inherent limitationsthat need to be accounted for when selecting the ranges of theindependent variables 180.28.2.4.2.99, 380.28.2.4.2.99. Once responsesurface testing helmets 180.28.4.12.99, 380.28.4.12.99 are created foreach type of manufacturing process in step 180.28.2.14, 380.28.2.14, theresponse surface testing helmets 180.28.4.12.99, 380.28.4.12.99 may becompared against one another to determine if their performance, inconnection with the energy attenuation layer testing protocol180.28.2.1.99, 380.28.2.1.99, is substantially similar in step180.28.2.16, 380.28.2.16. If the response surface testing helmet180.28.4.12.99, 380.28.4.12.99 performances are substantially similar,then the designer can optimize the manufacturing methods in step180.28.2.18, 380.28.2.18 by combining these manufacturing methods. Forexample, the designer may determine the side members of the energyattenuation assembly that are manufactured using a foam process performsubstantially similar side members of the energy attenuation assemblythat are manufactured using an additive process.

Additionally, the designer may determine the front members of the energyattenuation assembly that are manufactured using a foam process performcompletely different than front members of the energy attenuationassembly that are manufactured using an additive process. Based on theseexamples, the designer may combine these manufacturing methods in thecreation of the custom performance helmet model 380.28.99.Alternatively, the designer may determine that the members made usingthe additive manufacturing process perform substantially better thanmembers manufactured with other methods. In this example, the designerwill create the custom performance helmet model 380.28.99 using only theadditive manufactured members. Once the designer has optimizedmanufacturing in step 180.28.2.18, 380.28.2.18, the custom performancehelmet model 380.28.99 is outputted for use in the next steps indesigning and manufacturing the helmet 1000. It should be understoodthat the CP helmet model 380.28.99 may take the form of a finite elementmodel or any other digital model that contains mechanical properties andshape information that can be used later in the digital testing.

2) Brute Force Methodology

Instead of using a response surface methodology to create the CP helmetmodel 380.28.99, a brute force methodology 180.28.4, 380.28.4 may beused. Specifically, such a brute force methodology is disclosed in FIG.37. The first step in creating the CP helmet model 380.28.99 using bruteforce methodology 180.28.4, 380.28.4 is to determine an energyattenuation layer testing protocol in step 180.28.2.1, 380.28.2.1. Thisis done in the same manner as described above in connection with FIGS.34A-34B. The next steps are designed to test the selected complete stockhelmet model 170.4, 370.4 with its current configuration along withvariations of the selected complete stock helmet model 170.4, 370.4 todetermine the optimal configuration of the energy attenuation assemblyin light of the player's profile 120.99, 320.99. The first step in thesetests is to extract the dependent variables in step 180.28.4.2.4,380.28.4.2.4 from the selected complete stock helmet model 170.4, 370.4,the digital headform that is associated with the stock helmet model170.4, and extract the independent variables 180.28.4.2.2.99,380.28.4.2.2.99 based upon the selected complete stock helmet model170.4, 370.4 in step 180.28.4.2.2, 380.10.4.2.2.

Next, the designer will select a number of combinations of independentvariables. These combinations may be based on: (i) historical knowledge,(ii) a repetitive brute force process of picking a set of variables,testing the set of variables, selecting a new set of variables based onthe outcome of the test, (iii) a combination of the above methods.Regardless of how the independent variables are selected, they will beused to create rough testing helmets 180.28.2.4.8.99, 380.28.2.4.8.99.These rough testing helmets are then subjected to the energy attenuationlayer testing protocol 180.28.2.1.99, 380.28.2.1.99, wherein thefollowing values are recorded for each test within the energyattenuation layer testing protocol 180.28.2.1.99, 380.28.2.1.99: (i)peak linear acceleration, (ii) peak rotational acceleration, (iii) peakHITsp, and (iv) if the energy attenuation assembly bottomed out (e.g.,could not absorb any additional force) or if the energy attenuationassembly did not bottom out, then the distance that the energyattenuation assembly before it would bottom out in step 180.28.4.2.8,380.10.4.2.8. It should be understood that one of the testing helmetswill be directly based upon the selected complete stock helmet model170.4, 370.4.

After the rough testing helmet is determined for each set of variablesin step 180.28.4.4, 380.28.4.4, the designer selects the best performingrough testing helmets in step 180.28.4.6, 380.28.4.6 to create a bruteforce testing helmet 180.28.4.8.99, 380.28.4.8.99 in step 180.28.4.8.99,380.28.4.8.99. Next, the designer needs to verify that the brute forcetesting helmet 180.28.4.8.99, 280.28.4.8.99 meets all helmet standard(s)(e.g., player group—shape+impact based helmet standard, NOCSAE, andetc.). Once it has been verified that the brute force testing helmet180.28.4.8.99, 380.28.4.8.99 meets all helmet standard(s), the bruteforce testing helmet 180.28.4.8.99, 380.28.4.8.99 may undergo a visualinspection to ensure that it meets all manufacturing, marketing, andsales requirements. If the brute force testing helmet 180.28.4.8.99,380.28.4.8.99 does not meet any of these requirements, then the bruteforce testing helmet 180.28.4.8.99, 380.28.4.8.99 may be altered to meetthese requirements. Once the brute force testing helmet 180.28.4.8.99,380.28.4.8.99 meets these requirements, then the brute force testinghelmet 180.28.4.8.99, 380.28.4.8.99 is added to the collection of bruteforce testing helmets 180.28.4.8.99, 380.28.4.8.99, which will becompared against one another in the following steps.

Each of the above steps may optionally then be repeated for each methodof manufacturing (e.g., foam, Precision-Fit, and Additive Manufacturing)in step 180.28.4.10, 380.28.4.10. These methods must be performedindividually because each manufacturing method has inherent limitationsthat need to be accounted for when selecting the ranges of theindependent variables 180.28.4.2.2.99, 380.28.4.2.2.99. Once brute forcetesting helmets 180.28.4.8.99, 380.28.4.8.99 are created for each typeof manufacturing process in step 180.28.4.10, 380.28.4.10, the bruteforce testing helmet 180.28.4.8.99, 380.28.4.8.99 may be comparedagainst one another to determine if their performance, in connectionwith the energy attenuation layer testing protocol 180.28.2.1.99,380.28.2.1.99, is substantially similar in step 180.28.2.12,380.28.2.12. If the brute force testing helmet 180.28.4.8.99,380.28.4.8.99 performances are substantially similar, then the designercan optimize the manufacturing methods in step 180.28.4.14, 380.28.4.14by combining these manufacturing methods. Once the designer hasoptimized manufacturing in step 180.28.4.14, 380.28.4.14, the CP helmetmodel 380.28.99 is outputted for use in the next steps in designing andmanufacturing the helmet 1000. It should be understood that the customperformance helmet model 380.28.99 may take the form of a finite elementmodel or any other digital model that contains mechanical properties andshape information that can be used later in the digital testing.

3) Hybrid Methodology

Instead of just using a response methodology or a brute forcemethodology, the designer may desire to use a hybrid of thesemethodologies 180.28.6. The perimeter of each energy attenuation memberthat is contained within the energy attenuation assembly of the selectedcomplete stock helmet model 170.4, 370.4 is determined in step180.28.6.4, 380.28.6.4. Next, energy attenuation member models180.28.6.6.99, 380.28.6.6.99 are created using an energy attenuationengine to develop the internal structures for each energy attenuationmember in step 180.28.6.6, 380.28.6.6. Additional details about thecreation of these energy attenuation member models 180.28.6.6.99,380.28.6.6.99 are described in connection with FIG. 39. Referring toFIG. 39, this specific method starts with inputting the selectedcomplete stock helmet model 170.4, 370.4 along with the perimeter ofeach energy attenuation member. The energy attenuation engine utilizesthis information to extract the mechanical properties that areassociated with each energy attenuation member. Based on this extractedinformation, the energy attenuation engine determines the number andlocation of member regions. Next, the energy attenuation engineprocesses these regions to determine the properties (e.g., cell type,density, and angle) of these member regions.

The energy attenuation engine selects these member region variablesbased upon the information contained within its database or informationthat can be derived from information that is contained within itsdatabase. Information that may be contained within the energyattenuation engine database includes: (i) mechanical properties, (ii)thermal properties, (iii) manufacturing properties, and (iv) otherrelevant properties for combinations of the member region variables.These properties may be determined based upon: (i) actual data collectedfrom physical measurements or (ii) theoretical data generated bypredictive algorithms or learning algorithms. Examples of tests that maybe utilized to generate actual data include, but are not limited to: (i)ASTM D3574 testing protocols, including but not limited to, Tests B1, C,E, F, X6, 13, M, (ii) ISO 3386 testing protocol, (iii) ISO 2439 testingprotocol, (iv) ISO 1798 testing protocol, (v) ISO 8067 testing protocol,(vi) ASTM D638 testing protocol, (vii) ISO 37 testing protocol, (viii)ASTM D395 testing protocol, (ix) other types of compression analysis,(x) other types of elongation analysis, (xi) tensile strength analysis,or (xii) other similar techniques.

Referring to the member region variables, exemplary lattice cell typesare shown in FIG. 39, lattice angle may vary between 0 degrees and 180degrees. Additionally, the chemical compositions may include, but arenot limited to: polycarbonate, acrylonitrile butadiene styrene (ABS),nylon, polylactic acid (PLA), acrylonitrile styrene acrylate (ASA),polyoxymethylene (POM), rigid polyurethane, elastomeric polyurethane,flexible polyurethane, silicone, thermoplastic polyurethane (TPU),Agilus® 30, Tango®, other similar thermoplastics, other light sensitiveplastics or polymers (e.g., plastics that cure upon the exposure tocertain wavelengths of light, such as UV light), any combination of theabove materials with one another, where the materials are not blendedtogether prior to the forming an extent of the protective sports helmet,any combination of the above materials with one another, where thematerials are blended together prior to the forming of an extent ofprotective sports helmet, one or more of the above materials and astrength adding material (e.g, Kevlar or carbon fiber), where thematerials are not blended together prior to the forming an extent ofprotective sports helmet, one or more of the above materials and astrength adding material (e.g, Kevlar or carbon fiber), where thematerials are blended together prior to the forming an extent ofprotective sports helmets, hybrid of any of the disclosed material, orany other material that is specifically designed to absorb impact forceswithin a helmet.

Once member region variables are selected, then the energy attenuationmember model 180.28.6.6.99, 380.28.6.6.99 is created based upon theseselected variables. Exemplary energy attenuation member models180.28.6.6.75, 380.28.6.6.75 are shown in FIG. 40. In these examples,the energy attenuation engine created a single member region for thefront member of the energy attenuation assembly. The energy attenuationengine then analyzes various combinations of member region variables,some of these combinations are graphically shown in FIG. 40, in order tofind a combination of member region variables that created an energyattenuation member model 180.28.6.6.99, 380.28.6.6.99 that havemechanical properties that are similar to the energy attenuation memberfrom the selected complete stock helmet model 170.4, 370.4. This processis then repeated for each energy attenuation member contained within theenergy attenuation assembly.

It should be understood that the energy attenuation member models180.28.6.6.99, 380.28.6.6.99 may be created in the form of a finiteelement model or any other digital model that contains mechanicalproperties and shape information that can be used later in the digitaltesting. It should also be understood that the selection of the memberregions and their associated member region variables are not limited tostructures that can only be manufactured using additive manufacturingtechniques. Instead, the energy attenuation engine may consider andutilize any one of the following materials: expanded polystyrene (EPS),expanded polypropylene (EPP), plastic, foam, expanded polyethylene(PET), vinyl nitrile (VN), urethane, polyurethane (PU), ethylene-vinylacetate (EVA), cork, rubber, orbathane, EPP/EPS hybrid (Zorbium), brockfoam, or other suitable material or blended combination or hybrid ofmaterials. In using one of these materials, the member regions may beslightly altered to better represent the structures and properties ofthe select material.

Referring back to FIG. 38, the energy attenuation assembly of theselected complete stock helmet model 170.4, 370.4 is replaced with anenergy attenuation assembly created from the energy attenuation membermodels 180.28.6.6.99, 380.28.6.6.99. This combination is then testedusing the energy attenuation layer testing protocol 180.28.2.1,380.28.2.1, which takes into consideration the player's profile 120.99,320.99 in step 180.28.6.8, 380.28.6.8. The outcome of these tests isanalyzed in step 180.28.6.10, 380.28.6.10 to partition each energyattenuation member. FIG. 41 shows an example of how the energyattenuation member model 180.28.6.6.99, 380.28.6.6.99 may be dynamicallytested and how this dynamic testing can be utilized to partition theenergy attenuation member. In particular, this dynamic test suggestedthat the energy attenuation member be partitioned into four differentsegments. Where the first segment is shown in gray 180.28.6.10A,380.28.6.10A, the second segment is shown in gray to light yellow180.28.6.10B, 380.28.6.10B, the third segment is shown in yellow180.28.6.10C, 380.28.6.10C, and the fourth segment is shown in green180.28.6.10D, 380.28.6.10D. It should be understood that this is just anexample of embodiment and the dynamic testing of other energyattenuation members in connection with other selected complete stockhelmet models 170.4, 370.4 may create different numbers and locations ofmember regions.

Referring back to FIG. 38, once the energy attenuation members arepartitioned in step 180.28.6.10, 380.28.6.10, then the mechanicalproperties of each partitioned segment is optimized using one of theoptimization methods described above, including response surfacemethodology 180.28.2, 380.28.2, brute force methodology 180.28.4,380.28.4 or another optimization methodology in step 180.2.6.12,380.2.6.12. After step 180.28.6.12, 380.28.6.12 is performed, the CPhelmet model 180.28.99, 380.28.99 are generated and prepared for thenext steps in designing and manufacturing the helmet 1000. It should beunderstood that the CP helmet model 380.28.99 may take the form of afinite element model or any other digital model that contains mechanicalproperties and shape information that can be used later in the digitaltesting.

Instead of performing steps 180.28.6.6-180.28.6.10,380.28.6.6-380.28.6.10, a designer may elect to utilize a brute forcepartitioning approach in step 180.28.6.30, 380.28.6.30. This methodallows the designer to select the number and location of the memberregions. This selection may be based on historical knowledge or may bebased on physical testing of helmets or physical testing of helmetcomponents. For example, the designer may independently collect datafrom one of, or a combination of, the following: (i) placing sensors ina headform and testing the helmet using: (a) a linear impactor, (b) adrop tester, (c) a pendulum tester, or (d) other similar types of helmettesting apparatuses, (ii) placing sensors between the headform and theenergy attenuation assembly and testing the helmet using the aboveapparatuses, (iii) placing sensors between the energy attenuationassembly and the helmet shell and testing the helmet using the aboveapparatuses, (iv) placing sensors on the external surface of the shelland testing the helmet using the above apparatuses, (v) using a linearimpactor, a tensile strength machine, or another similar apparatus totest individual helmet components, (vi) using ASTM D3574 testingprotocols, including but not limited to, Tests B1, C, E, F, X6, 13, M,(vii) using ISO 3386 testing protocol, (viii) using ISO 2439 testingprotocol, (ix) data collected using ISO 1798 testing protocol, (x) usingISO 8067 testing protocol, (xi) using ASTM D638 testing protocol, (xii)using ISO 37 testing protocol, (xiii) using ASTM D395 testing protocol,or (xiv) other similar techniques.

FIGS. 42-43 show exemplary component regions that were created using abrute force method. Specifically, FIG. 42 shows six differentembodiments of the rear combination member, which is split intopartitions lengthwise using the brute force method. The first exemplaryembodiment contained within FIG. 42, which is labeled A and is in theupper right, contains two component regions. A first region is shown ingreen 180.28.6.30.2.2, 380.28.6.30.2.2, while the second region is shownin blue 180.28.6.30.2.4, 380.28.6.30.2.4. The second and fourthexemplary embodiment that are labeled B and D contains three componentregions, wherein one is green 180.28.6.30.2.2, 380.28.6.30.2.2, one isblue 180.28.6.30.2.4, 380.28.6.30.2.4, and one is in between green andblue 180.28.6.30.2.6, 380.28.6.30.2.6. The third exemplary embodiment islabeled C and contains four component regions, wherein one is green180.28.6.30.2.2, 380.28.6.30.2.2, one is blue 180.28.6.30.2.4,380.28.6.30.2.4, and one is red 180.28.6.30.2.8, 380.28.6.30.2.8, andone is between green and red 180.28.6.30.2.10, 380.28.6.30.2.10. Thefifth exemplary embodiment is labeled E and contains seven componentregions, wherein one is green 180.28.6.30.2.2, 380.28.6.30.2.2, one isblue 180.28.6.30.2.4, 380.28.6.30.2.4, one is red 180.28.6.30.2.8,380.28.6.30.2.8, one is between green and red 180.28.6.30.2.10,380.28.6.30.2.10, one is between green and blue 180.28.6.30.2.6,380.28.6.30.2.6, and one is yellow 180.28.6.30.2.12, 380.28.6.30.2.12.Lastly, the sixth exemplary embodiment is labeled F and contains fourcomponent regions, wherein one is green 180.28.6.30.2.2,380.28.6.30.2.2, one is blue 180.28.6.30.2.4, 380.28.6.30.2.4, one isred 180.28.6.30.2.8, 380.28.6.30.2.8, and one is between green and blue180.28.6.30.2.6, 380.28.6.30.2.6.

FIG. 43 shows six different embodiments of the energy attenuationmember, which is split into partitions lengthwise using the brute forcemethod. The first and third exemplary embodiment contained within FIG.43, which are labeled A and C contain two component regions. A firstregion is shown in green 180.28.6.30.4.2, 380.28.6.30.4.2, while thesecond region is shown in blue 180.28.6.30.4.4, 380.28.6.30.4.4. In thisexample, the first region may have mechanical properties that aredesigned to increase the comfort of the fit, while the second region mayhave mechanical properties that are designed to absorb impacts. Thesecond exemplary embodiment that is labeled B contains three componentregions, wherein one is green 180.28.6.30.4.2, 380.28.6.30.4.2, one isblue 180.28.6.30.4.4, 380.28.6.30.4.4, and one is red 180.28.6.30.4.8,380.28.6.30.4.8. The fourth exemplary embodiment is labeled D andcontains five component regions, wherein one is green 180.28.6.30.4.2,380.28.6.30.4.2, one is blue 180.28.6.30.4.4, 380.28.6.30.4.4, one isred 180.28.6.30.4.8, 380.28.6.30.4.8, one is between green and green180.28.6.30.4.6, 380.28.6.30.4.6, and one is blue to yellow180.28.6.30.4.16, 380.28.6.30.4.16. The fifth exemplary embodiment islabeled F contains five component regions, wherein one is green180.28.6.30.4.2, 380.28.6.30.4.2, one is blue 180.28.6.30.4.4,380.28.6.30.4.4, one is red 180.28.6.30.4.8, 380.28.6.30.4.8, one isbetween blue and green 180.28.6.30.4.6, 380.28.6.30.4.6, and one isbetween red and green 180.28.6.30.4.10, 380.28.6.30.4.10. The finalexemplary embodiment is labeled E contains six component regions,wherein one is green 180.28.6.30.4.2, 380.28.6.30.4.2, one is blue180.28.6.30.4.4, 380.28.6.30.4.4, one is red 180.28.6.30.4.8,380.28.6.30.4.8, one is yellow 180.28.6.30.4.12, 380.28.6.30.4.12, oneis orange 180.28.6.4.18, 380.28.6.30.4.18, and one is brown180.28.6.30.4.20, 380.28.6.30.4.20.

Referring back to FIG. 38, once the energy attenuation members arepartitioned in step 180.28.6.30, 380.28.6.30, then the mechanicalproperties of each partitioned segment is optimized using one of theoptimization methods described above, including response surfacemethodology 180.28.2, 380.28.2, brute force methodology 180.28.4,380.28.4, or another optimization methodology in step 180.2.6.12,380.2.6.12. After step 180.28.6.30, 380.28.6.30 is performed, the CPhelmet model 380.28.99 is generated and prepared for the next steps indesigning and manufacturing the player specific helmet.

B) Custom Performance Energy Attenuation Assembly Created from Scratch

In an alternative embodiment, the CS helmet model 280.50 may be createdfrom scratch. In this embodiment, the designer may input the energyattenuation layer testing protocol 180.28.2.1.99, 380.28.2.1.99 that wasdescribed above in connection with step 180.28.2.1, 380.28.2.1. Afterthis energy attenuation layer testing protocol 180.28.2.1.99,380.28.2.1.99, the system may utilize a brute force method (e.g.,similar to the method discussed above), a dynamic FE engine, a learningalgorithm, a neural network-based algorithm, or a combination of theseto generate the best performing CS helmet model 280.50 in light of theenergy attenuation layer testing protocol 180.28.2.1.99, 380.28.2.1.99.

3. Custom Performance and Custom Shaped Energy Attenuation Assembly

Custom performance and custom shaped (CP+CS) energy attenuation assemblycan be created using a combination of the techniques and methodologiesthat were discussed above in connection with the creation of the CSenergy attenuation assembly and the CP energy attenuation assembly. Forthe sake of brevity, the combination of these processes will not bedisclosed again. Nevertheless, the creation of the CP+CS energyattenuation assembly starts by creating a digital model of the CP+CSenergy attenuation assembly in connection with 180.10. Once the digitalmodel is created in step 180.10, then the digital model is modified bythe process disclosed in connection with forming the CP energyattenuation assembly. This modification creates the CP+CS helmet model180.28.99, which is prepared for the next steps in designing andmanufacturing the player specific helmet.

G. Generate Player Specific Helmet Model

The next step in this method is to create the player specific helmetmodel 190.12.99, 290.12.99, 390.12.99 from: (i) the CS+CP helmet model180.28.99, (ii) CS helmet model 280.50, or (iii) CP helmet model380.28.99. Details about the creation of the complete stock helmetmodels 190.12.99, 290.12.99, 390.12.99 are described in greater detailin FIG. 44. Referring now to FIG. 44, the first steps in this method areinputting the CS+CP, CS, or CP helmet models 180.28.99, 280.50,380.28.99 and determining the perimeter of: (i) each energy attenuationmember or (ii) each energy attenuation segment in step 190.2, 290.2,390.2. Next, CS+CP, CS, and CP helmet models 180.28.99, 280.50,380.28.99 along with the perimeter of: (i) each energy attenuationmember or (ii) each energy attenuation segment are entered into theenergy attenuation engine to develop energy attenuation member models190.8.99, 290.8.99, 390.8.99 in step 190.8, 290.8, 390.8. The energyattenuation member models 190.8.99, 290.8.99, 390.8.99 are created usingthe same steps that are described above in connection with FIG. 39 andfor the sake of brevity will not be repeated here.

Below are a number of exemplary embodiments of the front energyattenuation member model that may be created in step 190.8, 290.8,390.8. In the first exemplary embodiment, the chemical composition andthe structural makeup of the front energy attenuation member 2010, 3010may be consistent throughout the model. Specifically, the front energyattenuation member model may be comprised of: (i) a consistent blend oftwo types of polyurethane and (ii) a single lattice cell type. In asecond embodiment, the chemical composition of the front energyattenuation member model may be consistent throughout the entire model,while the structural makeup may vary between member regions.Specifically, the model may have: (i) a consistent blend of two types ofpolyurethane, (ii) a first region, which has a first lattice cell typeand a first density, and (iii) second region, which has a first latticecell type and a second density. In this example, the second latticedensity may be greater or denser than the first lattice density.Increasing the lattice density, while keeping all other variables (e.g.,lattice cell type, material type, etc.) consistent will make the modelharder. In other words, it will take more force to compress the model;thus, allowing the model to absorb greater impact forces withoutbecoming fully compressed (otherwise known as bottoming out).

In a third embodiment, the chemical composition of the front energyattenuation member model may be consistent throughout the model, whilethe structural makeup changes in various regions of the model.Specifically, the front energy attenuation member model may have:between (i) 1 and X different lattice cell types, where X is the numberof lattice cells contained within the model, (ii) preferably between 1and 20 different lattice cell types, and (iii) most preferably between 1and 10 different lattice cell types. Additionally, the front energyattenuation member model may also have: (i) between 1 and X differentlattice densities, where X is the number of lattice cells containedwithin the model, (ii) preferably between 1 and 30 different latticedensities, and (iii) most preferably between 1 and 15 different latticedensities. Further, the front energy attenuation member may also have:(i) between 1 and X different lattice angles, where X is the number oflattice cells contained within the model, (ii) preferably between 1 and30 different lattice angles, and (iii) most preferably between 1 and 15different lattice angles. Specifically, this embodiment may have: (i) aconsistent blend of two types of polyurethane, (ii) a first regionhaving a first lattice cell type and a first density, (iii) a secondregion having a first lattice cell type and a second density, and (iv) athird region having a second lattice cell type and a first density.

In a fourth embodiment, the chemical composition of the front energyattenuation member model may change in various regions of the model,while the structural makeup is consistent throughout the entire model.Specifically, the front energy attenuation member model may have: (i)between 1 and X different chemical compositions, where X is the numberof lattice cells contained within the model, (ii) preferably between 1and 3 different chemical compositions, and most (iii) preferably between1 and 2 different chemical compositions. In this exemplary embodiment,front energy attenuation member model may have: (i) a first region madefrom a first ratio of two polyurethanes, (ii) a second region made froma second ratio of one type of two polyurethanes, and (iii) a consistentstructural makeup of a single lattice cell type.

In a fifth embodiment, both the structural makeup and the chemicalcompositions may vary within the front energy attenuation member model.In this exemplary embodiment, the model has: (i) a first region madefrom a first ratio of two polyurethanes, (ii) a second region made froma second ratio of different polyurethanes, (iii) a third region, whichhas a first lattice cell type and a first density, (iv) a fourth region,which has a first lattice cell type and a second density, (v) a fifthregion, which has a second lattice cell type and a third density, and(vi) a sixth region, which has a third lattice cell type and a firstdensity. It should be understood that while the front energy attenuationmember model is discussed above in connection with the five exemplaryembodiments, the structural and chemical composition of these fiveexemplary embodiments may be applied to any one of the energyattenuation members contained within the energy attenuation assembly.Additionally, it should be understood that the selected complete stockhelmet 170.4, 270.4, 370.4 or selected stock helmet component mayinclude the above disclosed combinations of these structural andchemical compositions. See U.S. patent application Ser. No. 16/543,371.

Once the energy attenuation member models are created in step 190.8,290.8, 390.8, the player specific helmet models 190.12.99, 290.12.99,390.12.99 are created based upon the CS+CP, CS, and CP helmet models180.28.99, 280.10.99, 380.28.99 and their associated energy attenuationmember models 190.8.99, 290.8.99, 390.8.99 in step 190.12, 290.12,390.12. It should be understood that the complete stock helmet models190.12.99, 290.12.99, 390.12.99 may take the form of a finite elementmodel or any other digital model that contains mechanical properties andshape information that can be used later in the digital testing. FIGS.45A-45B show an assembled version of an exemplary 3D energy attenuationmember models 190.8.99, 290.8.99, 390.8.99, which are contained withinthe complete stock helmet model 190.12.99, 290.12.99, 390.12.99.

Referring back to FIG. 44, the complete stock helmet models 190.12.99,290.12.99, 390.12.99 are digitally tested to determine if the impactresponses substantially matches the impact responses of the CS+CP, CS,and CP helmet models 180.28.99, 280.10.99, 380.28.99 in step 190.14,290.14, 390.14. The computerized testing system performs this checkbecause the energy attenuation member models may not be able to exactlymatch the mechanical properties of the energy attenuation members thatare contained within the CS+CP, CS, and CP helmet models 180.28.99,280.10.99, 380.28.99. Thus, this step helps ensure that any changes tothe energy attenuation members do not substantially alter theperformance of the helmet. To perform this check, both the CS+CP, CS,and CP helmet models 180.28.99, 280.10.99, 380.28.99 and the completestock helmet model 190.12.99, 290.12.99, 390.12.99 are digitally tested.FIG. 46 shows the digital testing of the complete stock helmet models190.12.99, 290.12.99, 390.12.99.

Referring back to FIG. 44, if the impact response of the complete stockhelmet model 190.12.99, 290.12.99, 390.12.99 does not substantiallymatch the CS+CP, CS, and CP helmet models 180.28.99, 280.10.99,380.28.99 in step 190.14, 290.14, 390.14, then the electronic device 10determines if it is possible to physically manufacture the CS+CP, CS,and CP helmet models 180.28.99, 280.10.99, 380.28.99 in step 190.16,290.16, 390.16. If it appears to be possible in step 190.16, 290.16,390.16, then the energy attenuation member models are modified in step190.10, 290.10, 390.10 to better match the performance of the energyattenuation members contained within the CS+CP, CS, and CP helmet models180.28.99, 280.10.99, 380.28.9. Alternatively, if it is determined thatthe CS+CP, CS, and CP helmet models 180.28.99, 280.10.99, 380.28.9cannot be manufactured, then the ranges of the variables are altered instep 190.18, 290.18, 390.18 and these optimization steps are re-run. Ina further alternative, if the impact response of the complete stockhelmet model 190.12.99, 290.12.99, 390.12.99 substantially matches theCS+CP, CS, and CP helmet models 180.28.99, 280.10.99, 380.28.99 in step190.14, 290.14, 390.14, then the complete stock helmet models aregenerated and outputted for use in the next steps in designing andmanufacturing the helmet 1000.

H. Manufacture Player Specific Helmet Model With the Energy AttenuationAssembly

Referring to FIG. 1, the next step is to manufacture player specifichelmet based on the player specific helmet model 190.12.99, 290.12.99,390.12.99. Details about the manufacturing of the player specific helmet195.30.99, 295.30.99, 395.30.99 are described in greater detail in FIG.47. Referring now to FIG. 47, the first step in this process isinputting the player specific helmet model 190.12.99, 290.12.99,390.12.99. Next, a method of manufacturing the outer shell is selectedin step 195.2, 295.2, 395.2. The selected manufacturing method mayinclude: injection molding, thermoforming, gas-assisted molding,reaction-injection molding, or other similar manufacturing types. Itshould be understood that the selected manufacturing type should be ableto accurately produce the outer shell 195.2.99, 295.2.99, 395.2.99 forthe prototype helmets 195.30.99, 295.30.99, 395.30.99, whose mechanicaland physical properties are similar to the outer shell contained withinthe complete stock helmet model 190.12.99, 290.12.99, 390.12.99.

Once the outer shells 195.2.99, 295.2.99, 395.2.99 are produced in step195.2, 295.2, 395.2, the designer selects the method of manufacturingthe energy attenuation member models in step 195.4, 295.4, 395.4 thatwas previously selected during the design of the energy attenuationmember models. One method that may be selected is an additivemanufacturing method, which includes: (i) VAT photopolymerization195.4.2.2, 295.4.2.2, 395.4.2.2, (ii) material jetting 195.4.2.4,295.4.2.4, 395.4.2.4, (iii) material extrusion 195.4.2.6, 295.4.2.6,395.4.2.6, (iv) binder jetting 195.4.2.8, 295.4.2.8, 395.4.2.8, or (v)power bed fusion 195.4.2.10, 295.4.2.10, 395.4.2.10. In particular, VATphotopolymerization 195.4.2.2, 295.4.2.2, 395.4.2.2 manufacturingtechnologies include: Stereolithography (“SLA”), Digital LightProcessing (“DLP”), Direct UV Processing (“DUP”), or Continuous LiquidInterface Production (“CLIP”). Specifically, SLA can be done through anupside-down approach or a right-side-up approach. In both approaches, aUV laser is directed by at least one mirror towards a vat of liquidphotopolymer resin. The UV laser traces one layer of the object (e.g.,energy attenuation member model) at a time. This tracing causes theresin to selectively cure. After a layer is traced by the UV laser, thebuild platform moves to a new location, and the UV laser traces the nextlayer. For example, this method may be used to manufacture the energyattenuation member models, if they are made from a rigid polyurethane,flexible polyurethane, elastomeric polyurethane, a mixture of any ofthese polyurethanes, or any similar materials.

Alternatively, a DLP process uses a DLP chip along with a UV lightsource to project an image of the entire layer through a transparentwindow and onto the bottom of a vat of liquid photopolymer resin.Similar to SLA, the areas that are exposed to the UV light are cured.Once the resin is cured, the vat of resin tilts to unstick the curedresin from the bottom of the vat. The stepper motor then repositions thebuild platform to prepare to expose the next layer. The next layer isexposed to the UV light, which cures the next layer of resin. Thisprocess is repeated until the entire model is finished. DUP uses aprocess that is almost identical to DLP, the only difference is that theDLP projector is replaced in DUP with either: (i) an array of UV lightemitting diodes (“LEDs”) and a liquid crystal display (“LCD”), whereinthe LCD acts as a mask to selectively allow the light from the LEDs topropagate through the LCD to selectively expose the resin or (ii) a UVemitting organic liquid crystal display (“OLED”), where the OLED acts asboth the light source and the mask. Like SLA, this process may be usedto manufacture the energy attenuation member models, if they are madefrom a rigid polyurethane, flexible polyurethane, elastomericpolyurethane, a mixture of any of these polyurethanes, or any similarmaterials.

Similar to DLP and DUP, CLIP uses a UV light source to set the shape ofthe object (e.g., energy attenuation member model). Unlike DLP and DUP,CLIP uses an oxygen permeable window that creates a dead zone that ispositioned between the window and the lowest cured layer of the object.This dead zone helps ensure that the object does not stick to the windowand thus the vat does not need to tilt to unstick the object from thewindow. Once the shape of the object is set by the UV light, the objectis fully cured using an external thermal source or UV light. Informationabout CLIP, materials that can be used in connection with CLIP, andother additive manufacturing information are discussed in J. R.Tumbleston, et al., Additive manufacturing. Continuous liquid interfaceproduction of 3D objects. Science 347, 1349-1352 (2015), which is fullyincorporated herein by reference for any purpose. Like SLA and DLP, thisprocess may be used to manufacture the energy attenuation member models,if they are made from a rigid polyurethane, flexible polyurethane,elastomeric polyurethane, a mixture of any of these polyurethanes, orany similar materials.

Material jetting 195.4.2.4, 295.4.2.4, 395.4.2.4 manufacturingtechnologies include: PolyJet, Smooth Curvatures Printing, or Multi-JetModeling. Specifically, droplets of material are deposited layer bylayer to make the object (e.g., energy attenuation member model) andthen these droplets are either cured by a light source (e.g., UV light)or are thermally molten materials that then solidify in ambienttemperatures. This method has the benefit of being able to print colorswithin the object; thus, a team's graphics or the player's name may beprinted into the energy attenuation assembly. Material extrusion195.4.2.6, 295.4.2.6, 395.4.2.6 manufacturing technologies include:Fused Filament Fabrication (“FFF”) or Fused Deposition Modeling (“FDM”).Specifically, materials are extruded through a nozzle or orifice intracks or beads, which are then combined into multi-layer models. TheFFF method allows for the selective positioning of different materialswithin the object (e.g., energy attenuation member model). For example,one region of the energy attenuation member model may only containsemi-rigid polyurethane, where another region of the energy attenuationmember model contains alternating layers of rigid polyurethane andflexible polyurethane.

Binder jetting 195.4.2.8, 295.4.2.8, 395.4.2.8 manufacturingtechnologies include: 3DP, ExOne, or Voxeljet. Specifically, liquidbonding agents are selectively applied onto thin layers of powderedmaterial to build up parts layer by layer. Additionally, power bedfusion 195.4.2.10, 295.4.2.10, 395.4.2.10 manufacturingtechnologies/products include: selective laser sintering (“SLS”), directselective laser melting (“SLM”), selective heat sintering (“SHS”), ormulti jet fusion (“MJF”). Specifically, powdered materials areselectively consolidated by melting it together using a heat source suchas a laser or electron beam. Another method that the designer may selectis a manufacturing method that is described within U.S. patentapplication Ser. No. 15/655,490 in 195.4.4, 295.4.4, 395.4.4 or anyother method for manufacturing the energy attenuation member models in195.4.6, 295.4.6, 395.4.6.

Next in step 195.6, 295.6, 395.6, the energy attenuation member modelsare prepared for manufacturing based upon the selected manufacturingmethod in step 195.4, 295.4, 395.4. An example of such preparation inconnection with CLIP, may include: (i) providing the energy attenuationmember model in an Object file (.obj), Stereolithography (.stl), a STEPfile (.step), or any other similar file type, (ii) selecting an extentof the model that will be substantially flat and placing that in contactwith the lowermost printing surface, (iii) arranging the other modelswithin the printing area, (iv) slicing all models, and (v) reviewing theslices of the models to ensure that they properly manufacture the energyattenuation member models. An example of preparing the energyattenuation member models for manufacturing is shown in FIG. 48.

After the energy attenuation member models are prepared formanufacturing in step 195.6, 295.6, 395.6, the designer physicallymanufactures the energy attenuation member models in step 195.8, 295.8,395.8. An example of manufacturing the energy attenuation member modelsusing the CLIP technology is shown in FIGS. 49A-49C. It should also beunderstood that the selected complete stock helmet 170.4 can bemanufactured using any of the above described methods, as thesemanufacturing methods were discussed during the formation of these stockhelmets 170.4. See U.S. patent application Ser. No. 16/543,371, which isincorporated herein by reference. In fact, FIGS. 55A-57B, 60A-61B,63A-66B show exemplary embodiments of the energy attenuation assembly2000 of the selected complete stock helmet 170.4 that was manufacturedusing CLIP technology.

I. Exemplary Embodiment of a Protective Contact Sports Helmet

FIGS. 50A-54B are images of the helmet 1000 that has been selected forthe player based on the player's profile 120.99, 220.99, 320.99. Thehelmet 1000 includes the shell 1012, a facemask or faceguard 1200, achin strap assembly 1300, and an energy attenuation assembly 2000, 3000.The facemask or faceguard 1200 is attached at upper and lower frontalregions of the shell 1012 by connectors 1210 that are removably coupledto the shell by an elongated fastener 1215. The faceguard 1200 comprisesan arrangement of elongated and intersecting members and is designed tospan a frontal opening in the shell to protect the facial area and chinof the player.

As shown in FIGS. 50A-54B, the shell 1012 includes an outer shellsurface 1016 featuring complex contours and facets. The shell 1012 alsoincludes a crown portion 1018 defining a top region of the helmet 1000,a front portion 1020 generally extending forwardly and downwardly fromthe crown portion 1018, left and right side portions 1024 extendinggenerally downwardly and laterally from the crown portion 1018, and arear portion 1022 extending generally rearwardly and downwardly from thecrown portion 1018. The left and right side portions 1024 each includean ear flap 1026 generally positioned to overlie and protect the earregion of the player P when the helmet 1000 is worn. Each ear flap 1026may be provided with an ear hole 1030 to improve hearing for the wearer.The shell 1012 is symmetric along a vertical plane dividing the shell1012 into left and right halves. When the helmet 1000 is worn by theplayer P, this vertical plane is aligned with the midsagittal plane thatdivides the player P (including his head) into symmetric right and lefthalves, wherein the midsagittal plane is shown in the NOCSAE standardND002 for newly manufactured football helmets. Therefore, features shownin Figures as appearing in one half of the shell 1012 are also presentin the other half of the shell 1012.

The shell 1012 also includes a pair of jaw flaps 1034, with each jawflap 1034 generally extending forwardly from one of the ear flaps 1026for protection of the mandible area of the player P. In the illustratedconfiguration, the jaw flaps 1034 also include a lower faceguardattachment region 1035. An upper faceguard attachment region 1036 isprovided near a peripheral frontal edge 1013 a of the shell 1012 andabove the ear hole 1030. Each attachment region 1035, 1036 includes anaperture 1033 that receives a fastener extending through the faceguardconnector 1210 to secure the faceguard 1200 to the shell 1012.Preferably, the lower faceguard attachment region 1035 is recessedinward compared to the adjacent outer surface 1034 a of the jaw flap1034, and the upper faceguard attachment region 1036 is recessed inwardcompared to the adjacent outer surface 1026 a of the ear flap 1026. Asshown in FIGS. 51A-51B, there is an angled transition wall 1038extending inward from the ear flap outer surface 1026A and the jaw flapouter surface 1034 a to the recessed attachment regions 1035, 1036. Theangled transition wall 1038 extends from the central frontal edge 1013 bin the front portion 1020 rearward and then downward to a lower edge1037 of the jaw flap 1034. A chin strap securement member 1310 ispositioned rearward of the upper faceguard attachment region 1036 and isconfigured to receive a strap member of the chin strap assembly 1300.

The helmet 1000 also includes an integrally raised central band 1062that extends from the front shell portion 1020 across the crown portion1018 to the rear shell portion 1022. The band 1062 is defined by a pairof substantially symmetric raised sidewalls or ridges 1066 that extendupwardly at an angle from the outer shell surface 1016. When viewed fromthe side, the sidewalls 1066 define a curvilinear path as they extendacross the crown portion 1018 to the rear shell portion 1022. Asexplained in detail below, a front portion 1064 of the band 1062 iscoincident with an impact attenuation member 1042 and is positioned adistance above the central frontal edge 1013 b. Referring to FIG. 52A,the band 1062 has a width that increases as the band 1062 extends fromthe front shell portion 1020 across the crown portion 1018 to the rearshell portion 1022. As shown in FIG. 53A, a rear portion 1068 of theband 1062 is coincident with and merges with a rear raised band 1070that extends transversely between the left and right side portions 1024of the shell 1012. Referring to FIG. 51A, the left sidewall 1066 aintersects with an upper left sidewall 1072 a of the transverse band1070, and the right sidewall 1066B intersects with an upper rightsidewall 1072B of the transverse band 1070, wherein each of theseintersections defines a substantially right angle. A lower transversesidewall 1074 extends from the outer shell surface 1016 along the lengthof the transverse rear band 1070. Similar to the sidewalls 1066, therear band sidewalls 1072, 1074 are sloped, meaning they extend outwardlyand upwardly at an angle from the outer shell surface 1016. Referring toFIG. 51A, a lower channel 1080 extends transversely below the raisedrear band 1070 and above a lower rear shell edge 1081.

As shown in the Figures, the helmet 1000 further includes numerous ventopenings that are configured to facilitate circulation within the helmet1000 when it is worn by the player P. A first pair of vent openings 1084are formed in the crown portion 1018, wherein the left vent opening1084A is substantially adjacent the left side wall 1066A and the rightvent opening 1084B is substantially adjacent to the right sidewall1066B. The left and right vent openings 1084A,B have a longitudinalcenterline that is generally aligned with an adjacent extent of therespective sidewall 1066A,B. A second pair of vent openings 1086 areformed in the rear shell portion 1022, wherein the left vent opening1086A is substantially adjacent to the left sidewall 1066A and left bandsidewall 1072A, and the right vent opening 1086B is substantiallyadjacent the right sidewall 1066B and right band sidewall 1072B. Theleft and right vent openings 1086A,B have a longitudinal centerline thatis generally aligned with the respective sidewall 1066A,B. In thismanner, the left first and second vent openings 1084A, 1086A aresubstantially aligned along the left sidewall 1066A, and the right firstand second vent openings 1084A, 1086A are substantially aligned alongthe right sidewall 1066B.

Referring to FIG. 53A, a third pair of vent openings 1088 are formed inthe rear shell portion 1022 below the rear raised band 1070, wherein theleft vent opening 1088A is positioned adjacent a left ridge 1087A formedby an angled side wall 1085A and the right vent opening 1088B ispositioned adjacent a right ridge 1087B formed by an angled sidewall1085B. The third vent openings 1088A,B have a longitudinal centerlinethat is oriented substantially perpendicular to the raised central band1062, and that would intersect, if extended, the ear opening 1030. Afourth pair of vent openings 1090 are formed in the front shell portion1020, wherein the left vent opening 1090A is positioned adjacent to aleft frontal ridge 1092A and the right vent opening 1092A is positionedadjacent a right frontal ridge 1092B. The frontal ridges 1097A,B arelocated between the front shell portion 1020 and the side portion 1024and thus generally overlie the temple region of the player P when thehelmet 1000 is worn. Referring to FIGS. 63A-63B, the frontal ridges1097A,B are also formed from an angled sidewall and include an upperinclined segment 1089A,B, a declining intermediate segment 1091A,B, anda lower segment 1093A,B that extends rearward at a slight angle towardsthe side shell portion 1024. The fourth vent openings 1090A,B have amajor component 1095A,B, and a minor component 1097A,B wherein the majorcomponent 1095A,B is aligned with the upper segment 1089A,B and theintermediate segment 1091A,B, and the minor component 1097A,B has awidth that tapers as it extends along the lower segment 1093A,B. Theouter shell surface 1016 adjacent and rearward of the vent openings1090A,B is recessed relative to the outer shell surface 16 adjacent andforward of the frontal ridges 92A,B. The first, second, third and fourthvent openings 1084A,B, 1086A,B, 1088A,B and 1090A,B are cooperativelypositioned with voids in the energy attenuation assembly 2000 tofacilitate the flow of air through the helmet 1000.

A front portion 1064 of the helmet 1000, the central band 1062 has awidth of at least 2.0 inches, and preferably at least 2.25 inches, andmost preferably at least 2.5 inches and less than 3.5 inches. Proximatethe juncture of the raised central band 1062 and the raised rear band1070, the raised central band 1062 has a width of at least 4.0 inches,and preferably at least 4.25 inches, and most preferably at least 4.5inches and less than 5.0 inches. At this same juncture, the raised band1070 has a height of at least 1.25 inch, and preferably at least 1.5inches, and most preferably at least 1.5 inch and less than 2.0 inches.At the region where the terminal ends 1070A of the rear raised band 1070merges flush with the outer shell surface 16, slightly rearward of theear opening 1030 (see FIG. 51A), the terminal end 1070 a of the raisedband 1070 has a height of at least 0.75 inches, and preferably at least1.0 inch and less than 1.75 inch. Accordingly, the height of the raisedrear band 1070 tapers as each lateral band segment 1070 b extends fromthe raised central band 1062 forward towards the respective ear flap1026. Because the raised central band 1062 and the raised rear band 1070are formed as corrugations in the shell 1012, the foregoing dimensionscontribute to increasing the mechanical properties of the crown portion1018 and the rear shell portion 1022, namely the structural modulus(E_(s)), of these portions 1018, 1022. The structural modulus provides astiffness value of a respective portion of the helmet 1000 based uponits geometry. A higher structural modulus value corresponds to increasedstiffness of that portion of the helmet 1000.

The helmet shell 1012 also includes an impact attenuation system 1014,which is comprised of the impact attenuation member 1042 which adjustshow the portion of the helmet 1000, including the member, 42 responds toimpact forces compared to adjacent portions of the helmet 1000 lackingthe member 1042. The impact attenuation member 1042 is formed byaltering at least one portion of the shell 1012 wherein that alterationchanges the configuration of the shell 1012 and its local response toimpact forces. For example, in the illustrated configuration, the impactattenuation member 1042 includes an internal cantilevered segment orflap 1044 formed in the front shell portion 1020. Compared to theadjacent portions of the shell 1012 that lack the cantilevered segment1044, the front shell portion 1020 has a lower structural modulus(E_(s)) which improves the attenuation of energy associated with impactsto at least the front shell portion 20. Thus, the configuration of thehelmet 1000 provides localized structural modulus values for differentportions of the helmet 1000.

As shown in the Figures, the illustrated cantilevered segment 1044 isformed by removing material from the shell 1012 to define amulti-segment gap or opening 1046, which partially defines a boundary ofthe cantilevered segment 1044. Unlike conventional impact forcemanagement techniques that involve adding material to a helmet, theimpact attenuation system 1014 involves the strategic removal ofmaterial from the helmet 1000 to integrally form the cantileveredsegment 1044 in the shell 1012. The cantilevered segment 1044 dependsdownward from an upper extent of the front shell portion 1020 near theinterface between the front portion 1020 and the crown portion 1018. Thecantilevered segment 1044 includes a base 1054 and a distal free end 58and approximates the behavior of a living hinge when a substantiallyfrontal impact is received by the front shell portion 20. The lowermostedge of the free end 1058 is positioned approximately 1.5-2.5 inches,preferably 2.0 inches from the central frontal edge 13 b, wherein thelower shell portion 1020 a of the front shell portion 1020 istherebetween.

As shown in FIGS. 50B, 52A, the opening 1046 and the cantileveredsegment 1044 are generally U-shaped with an upward orientation, meaningthat they are oriented upwards towards the crown portion 1018. Theopening 1046 has a complex geometry with a number of distinct segments.A first generally vertical right segment 1046A extends downward andoutward from a right endpoint 1048A towards the right side of the frontshell portion 1020. A second generally vertical right segment 1046Bextends downward and inward from the first right segment 1046A to agenerally lateral segment 1049. Similarly, a first generally verticalleft segment 1047A extends downward and outward from a left endpoint1048B towards the left side of the front shell portion 1020. A secondgenerally vertical left segment 1047B extends downward and inward fromthe first left segment 1047A to the lateral segment 49. The lateralsegment 49 extends between the second right and left segments 1046B,1047B. The lowermost extent of the lower, second right and left segments1046B, 1047B is positioned approximately 1.5-2.5 inches, preferably 2.0inches from the central frontal edge 1013B. In the illustratedembodiment, the lateral segment 49 forms an obtuse angle with therespective second right and left segments 1046B, 1047B, and the firstright and left segments 1046A, 1047A form an obtuse angle with therespective second right and left segments 1046B, 1047B. Also, the leftand right endpoints 1048A,B have a substantially circular configurationwith a width that exceeds the width of the opening 46. Although theillustrated first and second segments 1046A,B, 1047A,B and the lateralsegment 1049 are substantially linear, these segments can be configuredas curvilinear or a combination of curvilinear and straight segments.Furthermore, the opening 1046 may be formed by more or less than thefive segments 1046A,B, 1047A,B and 1049, as shown, for example, in thealternative embodiments discussed below.

In the embodiment Figures, the raised central band 1062 and itssidewalls 1066A,B extend upward from the distal end 1058 across anintermediate portion 1059 and then beyond the base 1054 of thecantilevered segment 1044. In this manner, the leading edges of theraised central band 1062 and the sidewalls 1066A,B taper into and areflush with the distal end 1058 proximate the lateral segment 1049.Alternatively, the leading edges of the raised central band 1062 and thesidewalls 1066A,B are positioned above the distal end of 1058 and closerto the base 1054. In another alternative, the leading edge of the raisedcentral band 1062 and the sidewalls 1066A,B are positioned above thebase 1054, whereby the raised central band 1062 is external to thecantilevered segment 44. As shown in FIG. 54A, the shell 1012 alsoincludes an inner central bead 1019 formed from material added to theshell 1012, wherein the bead 1019 extends along the inner shell surface1017 from the crown portion 1018 to the cantilevered segment 1044. Thebead 1019 has a rounded nose 1019A that extends downward past the base1054 to the intermediate portion 1059 and towards the distal end 1058.Preferably, a major extent of the cantilevered segment 1044 has the samewall thickness as the other portions of the front shell portion 1020 andthe crown portion 1018. For example, the intermediate portion 1059 andthe distal end 1058 of the cantilevered segment 1044, the front shellportion 1020 and the crown portion 1018 have a nominal wall thickness of0.125-inch±0.005 inches. In addition, bosses 1053A,B are formed on theinner shell surface 1017 around the eyelets 1048A,B to increase thedurability of this region of the shell 1012 and cantilevered segment1044.

As shown in FIG. 51A, chin strap securement member 1310 is positionedrearward of the upper faceguard attachment region 1036 and is configuredto receive an upper strap member 1312 of the chin strap assembly 1300. Amulti-adjustable chin strap securement member 1320, which is positionedrearward of the lower faceguard attachment region 1035 and along a lowerside shell edge 1013C, is configured to receive a lower strap member1314 of the chin strap assembly 1300. The multi-adjustable chin strapsecurement member 1320 is received by a receptacle 1325 formed in alower portion of the shell 1012. In the use position shown in FIG. 1,the upper strap member 1312 extends between the upper peripheral portion1220 of the faceguard 1200 and the upper attachment region 1036. Morespecifically, the upper strap member 1312 extends through a gap orclearance formed between the outer surface of the upper attachmentregion 1036 and the inner surface of the upper peripheral faceguardportion 1220. The upper strap member 1312 can engage the second downwardsegment 1058C of the transition wall 58.

J. Exemplary Embodiment of a Stock Energy Attenuation Assembly for Usein a Protective Contact Sports Helmet

FIGS. 55A-57B, 60A-61B, 63A-66B show an assembled stock energyattenuation assembly 2000 for use in a protective contact sports helmet,such as the football helmet 1000, or a hockey helmet or lacrosse helmet.The stock energy attenuation assembly 2000 is comprised of: (i) a frontenergy attenuation member 2010, (ii) a crown energy attenuation member2050, (iii) left and right energy attenuation members 2100A,B, (iv) leftand right jaw energy attenuation members 2150A,B, (v) a rear energyattenuation member 2200, and (vi) occipital energy attenuation member2250. As shown in these figures and described below, the energyattenuation members contained within the stock energy attenuationassembly 2000 use different lattice cells, different lattice densities,different lattice angles, and different materials. The use of thesevarying structural designs and chemical compositions allows the designerto tune the lattice components in order to manage impact energies andforces, such as linear and rotational forces.

While additional details will be provided below, the exemplaryembodiment of the stock energy attenuation assembly 2000 contains atleast ten different member regions. The member regions are split amongstthe energy attenuation assembly 2000, as follows: (i) two regions withinthe front energy attenuation member 2010, (ii) one region within thecrown energy attenuation member 2050, (iii) two regions within the leftand right energy attenuation members 2100A,B, (iv) two regions withinthe left and right jaw energy attenuation members 2150A,B, (v) oneregion within the rear energy attenuation member 2200, and (vi) tworegions within the occipital energy attenuation member 2250. Theexemplary embodiment of the stock energy attenuation assembly 2000 alsoincludes at least five different strut based lattice cell types and atleast three different surface based lattice cell types. For example, thefront energy attenuation member 2010 includes a gyroid lattice cell2030, while the left and right energy attenuation members 2100A,Binclude an FRD lattice cell. Further, the exemplary embodiment of thestock energy attenuation assembly 2000 includes multiple differentlattice densities. These differences can be seen by visually comparingthe crown energy attenuation member 2050 with the rear energyattenuation member 2200. It should be understood that in differentembodiments, the energy attenuation assembly 2000 may have differentnumber of member regions, types of lattice cells, and lattice densityvalues. For example, the energy attenuation assembly 2000 may havebetween: (i) 1 and X different lattice cell types, where X is the numberof lattice cells contained within the assembly 2000, (ii) 1 and Ydifferent lattice member thicknesses, where Y is the number of latticecells contained within the assembly 2000, (iii) 1 and Z differentlattice densities, where Z is the number of lattice cells containedwithin the assembly 2000, and (iv) 1 and U different member regions,where U is the number of lattice cells contained within the assembly2000. In one exemplary embodiment, the lattice density of the frontenergy attenuation member may range between 4 to 17 pounds per cubicfoot and preferably between 4 to 9 pounds per cubic foot.

In addition to the above described structural differences, the energyattenuation assembly 2000 also includes different chemical compositions.In particular, the exemplary embodiment of the stock energy attenuationassembly 2000 is made from two different materials. The front energyattenuation member 2010 is made from a first blend or ratio of rigidpolyurethane and flexible polyurethane, while all other energyattenuation members 2050, 2100A,B, 2150A,B, 2200, 2250 are made from asecond blend or ratio of rigid polyurethane and flexible polyurethane.It should be understood that in different embodiments, the energyattenuation assembly 2000 may be made from: between (i) 1 and Xdifferent chemical compositions, where X is the number of lattice cellscontained within the assembly 2000, (ii) preferably between 1 and 20different chemical compositions, and (iii) most preferably between 1 and3 different chemical compositions.

As shown in FIGS. 55A-57B and, the front energy attenuation member 2010has a curvilinear configuration that corresponds to the curvature of theinner surface 1017 of the shell 1012 and the cantilevered segment 1044.The front energy attenuation member 2010 also has: (i) a recessedcentral region 2421 that facilitates engagement of the crown energyattenuation member 2050. When the helmet 1000 is worn by the player, thefront energy attenuation member 2010 engages the player's frontal boneor forehead while extending laterally between the player's templeregions and extending vertically from the player's brow line BL acrossthe player's forehead. The front energy attenuation member 2010 alsoincludes means 2006 for securing or coupling, such as hook and loopfasteners sold under VELCRO® or a snap connector, the energy attenuationmember 2010 to the inner shell surface 1017. As shown in FIG. 56A, thefront energy attenuation member 2010 also includes a surface or panelthat allows for indicia 2012, such as the manufacturer of the helmet1000, a team name, a player's name, and/or the month and year the memberwas manufactured. Further, the front energy attenuation member 2010includes a surface or panel that allows for a tracking device 2014, suchas a bar code or QR code. In other embodiments, the tracking device 2014may be RFID chips or other electronic chips that can be scanned from theexterior of the helmet and used for tracking purposes.

In this exemplary embodiment, the front energy attenuation member 2010is a non-homogeneous member, as it includes approximately five differentlayers or regions. The first layer of 2028 that is positioned adjacentto the curvature of the inner surface 1017 of the helmet shell 1012 isan exterior open skin 2020. First, this exterior skin 2020 is open andnot closed because there are holes 2022 formed therethrough. The use ofthis exterior open skin 2020 is desirable because it provides asubstantially smooth surface, which cannot be provided by the adjacentsurface based lattice cell. In this exemplary embodiment, this exteriorskin can have a thickness that is between 0.5 mm and 3 mm, andpreferably 1 mm. Adjacent to the exterior open skin 2020, is the energymanagement region 2024 of the front energy attenuation member 2010(shown in FIG. 59A). Overall, this energy management region 2024 isdesigned to absorb a majority of the linear and rotational energies thatare translated through the helmet shell 1012 to the front energyattenuation member 2010. This energy management region 2024 includes asurface based lattice cell, which in this exemplary embodiment is agyroid lattice cell 2030. Based on the safety regulations (e.g.,promulgated by NOCSAE) and tests that are utilized by third partytesting organizations (e.g., NFL, Virginia Tech, etc.), it is desirableto utilize a surface based lattice cell type over a strut based latticecell type for the energy management region 2024. In other words, thesurface based lattice cell types perform better than the strut basedlattice cell types in the energy management region 2024 in light of thecurrent requirements. In particular, a gyroid lattice cell 2030 is usedwithin this energy management region 2024. It should be understood thatin different embodiments, in connection with different testingrequirements, or if different materials are utilized, strut basedlattice cell types or different surface lattice cells may outperform thegyroid lattice cell 2030. As such, the use of any type of lattice cell,any density, any angle is contemplated by this disclosure.

An interior open skin 2032 is positioned adjacent to the energymanagement region 2024. Thus, the energy management region in 2024 ispositioned between exterior open skin 2020 and the interior open skin2032. The interior open skin 2032 is also positioned adjacent to thefitting region 2026 (shown in FIG. 57C). This interior open skin 2032acts as a divider between the fitting region 2026 and the energymanagement region 2024, which may allow for the presence of desirableboundary conditions. This fitting region 2026 includes a strut basedlattice cell 2034, which provides desirable fitting characteristics. Itshould be understood that in different embodiments or if differentmaterials are utilized, surface based lattice cell types or differentstrut based lattice cells may outperform the current strut based latticecell. As such, the use of any type of lattice cell, any density, anyangle is contemplated by this disclosure.

Finally, a closed skin 2202 is positioned adjacent to the fitting region2026 (see FIGS. 57A-57B). The closed skin 2202 creates a substantiallysmooth surface that is designed to come into contact with the player'sforehead. The skin 2202 is integrally formed as a part of the member2010 and as such the lattice cells on the side of the member 2010 blendinto the skin 2202 as the lattice cells approach the inner surface ofthe member 2010. This blending of the lattice cells into the skin 2202starts to occur prior to the shoulders 2018 of the member 2010.Utilizing the skin and starting the skin 2202 in this location helpsprevent the lattice cells from imprinting their pattern on the player'shead. In one embodiment, the skin 2202 has a thickness that is greaterthan 0.1 mm; however, it should be understood that the thickness of thisskin 2202 may be changed. It should also be understood that the skin2202 may extend around the side regions of the member 2010 or maycompletely encase the member 2010 (e.g., where the member has asubstantially smooth surface on the outside of all sides of the member2010).

FIGS. 58A-59B show compressions curves for two embodiments of the frontenergy attenuation member 2010, wherein the percent the member 2010 iscompressed is shown on the X-axis and the pressure (psi) it takes tocompress the member 2010 to that extent is shown on the Y-Axis. In otherwords, this graphs 58A and 59B show how much pressure must be exerted onthis two embodiments of the member 2010 to compress the embodiments ofthe member 2010 from 0% compression to 80% of its original thickness.Based on this the graphs shown in FIGS. 58A-58B, which are based on afirst embodiment of the front energy attenuation member 2010,compressing the member to 15% of its total thickness requires about 10psi, compressing the member to 25% of its total thickness requires about21 psi, and compressing the member to 60% of its total thicknessrequires about 80 psi. From the above disclosure, it should beunderstood that both the structural makeup (e.g., lattice cell types,lattice densities, lattice angles) and the chemical compositions mayvary depending on whether the front energy attenuation member 2010 isdesigned for: (i) all players, (ii) a specific position (e.g., lineman),(iii) a specific playing level (e.g., NCAA players), or (iv) a positionand playing level design (e.g., varsity quarterback).

As shown in FIGS. 55A-55E and 60A-60C, the crown energy attenuationmember 2050 has a curvilinear configuration that corresponds to thecurvature of the inner surface 1017 of the helmet shell 1012. The crownenergy attenuation member 2050 has a region that is designed to engagewith the front energy attenuation member 2010. Like the front energyattenuation member 2010, the crown energy attenuation member 2050includes: (i) means for securing or coupling 2006, such as hook and loopfasteners sold under VELCRO® or a snap connector, the members 2050 tothe inner shell surface 1017, (ii) indicia 2012, and (iii) trackingdevice 2014. The crown energy attenuation member 2050 includes a strutbased lattice cell that extends throughout the entire member and createsa substantially homogeneous member. This member 2050 can utilize asingle strut based lattice cell throughout the member 2050 because thecompression curve for the energy management region does not vary enoughto warrant the inclusion of an additional lattice cell type. Similarly,this member 2050 does not include an exterior open skin because, unlikea surface lattice cell, a strut based lattice cell can terminate at asurface without providing a non-smooth outer surface. In one exemplaryembodiment, the lattice density of the crown energy attenuation member2050 may range between 3 to 7 pounds per cubic foot. It should beunderstood that crown energy attenuation member 2050 has the sameflexibility in its structural makeup and chemical composition asdiscussed above and as such its structural makeup and/or the chemicalcomposition may differ from: (i) all other members within the energyattenuation assembly 2000, (ii) a percentage of the members within theenergy attenuation assembly 2000, or (iii) none of the members withinthe energy attenuation assembly 2000.

As shown in FIGS. 55A-57B, 61A-61B, the left and right energyattenuation members 2100A,B have a curvilinear configuration thatcorresponds to the curvature of the inner surface 1017 of an extent ofthe side shell portions 1024. The left and right energy attenuationmembers 2100A,B have regions that are designed to engage with the frontenergy attenuation member 2010. Like the front energy attenuation member2010, the left and right energy attenuation members 2100A,B include: (i)means for securing or coupling 2006, such as hook and loop fastenerssold under VELCRO® or a snap connector, the members 2150A,B to the innershell surface 1017, (ii) indicia 2012, and (iii) tracking device 2014.Also, in this exemplary embodiment, the left and right energyattenuation members 2100A,B is non-homogeneous, as they includeapproximately five different layers. The first layer that is positionedadjacent to the curvature of the inner surface 1017 of the helmet shell1012 is an exterior open skin 2020. The use of this exterior open skinis desirable because it provides a substantially smooth surface, whichcannot be provided by the adjacent surface based lattice cell. In thisexemplary embodiment, this exterior skin can have a thickness that isbetween 0.5 mm and 3 mm, and preferably 1 mm.

Adjacent to the exterior open skin 2020 is the energy management region2024 of the left and right energy attenuation members 2100A,B. Overall,this energy management region 2024 is designed to absorb a majority ofthe linear and rotational energies that are translated through thehelmet shell 1012. This energy management region 2024 includes a surfacebased lattice cell, which in this exemplary embodiment is a FRD. Aninterior open skin is positioned adjacent to the energy managementregion 2024. Thus, the energy management region 2024 is positionedbetween exterior open skin 2020 and the interior open skin. The interioropen skin is also positioned adjacent to the fitting region 2026. Thisinterior open skin may act as a divider between the fitting region 2026and the energy management region 2024, which may allow for the presenceof desirable boundary conditions. This fitting region 2026 includes astrut based lattice cell, which provides desirable fittingcharacteristics. It should be understood that in different embodimentsor if different materials are utilized, surface based lattice cell typesor different strut based lattice cells may outperform the current strutbased lattice cell. As such, the use of any type of lattice cell, anydensity, any angle is contemplated by this disclosure. In one exemplaryembodiment, the lattice density of the left and right energy attenuationmembers 2100A,B may range between 3 to 7 pounds per cubic foot.Additionally, it should be understood that the structural makeup and/orthe chemical compositions of the left and right energy attenuationmembers 2100A,B may differ from: (i) all other members within the energyattenuation assembly 2000, (ii) a percentage of the members within theenergy attenuation assembly 2000, or (iii) none of the members withinthe energy attenuation assembly 2000.

Finally, a closed skin 2202 is positioned adjacent to the fitting region2026 (see FIG. 61A). The closed skin 2202 creates a substantially smoothsurface that is designed to come into contact with the player'sforehead. The skin 2202 is integrally formed as a part of the members2100A,B and as such the lattice cells on the side of the members 2100A,Bblend into the skin 2202 as the lattice cells approach the inner surfaceof the member 2100A,B. This blending of the lattice cells into the skin2202 starts to occur prior to the shoulders 2018 of the members 2100A,B.Utilizing the skin and starting the skin 2202 in this location helpsprevent the lattice cells from imprinting their pattern on the player'shead. In one embodiment, the skin 2202 is between 0.1 mm and 10 mm;however, it should be understood that the thickness of this skin 2202may be changed. It should also be understood that the skin 2202 mayextend around the side regions of the member 2100A,B or may completelyencase the member 2100A,B (e.g., where the member has a substantiallysmooth surface on the outside of all sides of the member 2100A,B).

FIGS. 62A-62B show compressions curves for the left and right energyattenuation members 2100A,B, wherein the percent the members 2100A,B iscompressed is shown on the X-axis and the pressure (psi) it takes tocompress the members 2100A,B to that extent is shown on the Y-Axis. Inother words, this graph shows how much pressure must be exerted on thismember 2100A,B to compress the member 2010 from 0% compression to 80% ofits original thickness. Based on this graph, compressing the member2100A,B to 25% of its total thickness requires about 12 psi andcompressing the member to 50% of its total thickness requires about 56psi. In this exemplary embodiment, the left and right energy attenuationmembers 2100A,B require almost 50% less force to compress the members to25% of their thickness in comparison with the first embodiment of thefront energy attenuation member 2010. From the above disclosure, itshould be understood that both the structural makeup (e.g., lattice celltypes, lattice densities, lattice angles) and the chemical compositionsmay vary depending on whether the front energy attenuation member 2010is designed for: (i) all players, (ii) a specific position (e.g.,lineman), (iii) a specific playing level (e.g., NCAA players), or (iv) aposition and playing level design (e.g., varsity quarterback).

As shown in FIGS. 55A-57B, 63A-63B, the left and right jaw energyattenuation members 2150A,B have a curvilinear configuration thatcorresponds to the curvature of the inner surface 1017 of an extent ofthe ear flap 1026 portions of the shell 1012. The left and right jawenergy attenuation members 2150A,B are configured to engage with theleft and right energy attenuation members 2100A,B. Like the front energyattenuation member 2010, the left and right jaw energy attenuationmembers 2150A,B also includes: (i) means for securing or coupling 2006,such as hook and loop fasteners sold under VELCRO® or a snap connector,the energy attenuation members 2150A,B to the inner shell surface 1017,(ii) indicia 2012, and (iii) tracking device 2014. Also, in thisexemplary embodiment, the left and right jaw energy attenuation members2150A,B are non-homogeneous members, which include approximately fourdifferent layers. The first layer is an energy management region of theleft and right jaw energy attenuation members 2150A,B. Overall, thisenergy management region 2024 is designed to absorb a majority of thelinear and rotational energies that are translated through the helmetshell 1012. This energy management region 2024 includes a strut basedlattice cell. An interior open skin is positioned adjacent to the energymanagement region 2024 and a fitting region 2026. This interior openskin may act as a divider between the fitting region 2026 and the energymanagement region 2024, which may allow for the presence of desirableboundary conditions. This fitting region 2026 includes a strut basedlattice cell, which provides desirable fitting characteristics. Itshould be understood that in different embodiments or if differentmaterials are utilized, surface based lattice cell types or differentstrut based lattice cells may outperform the current strut based latticecell. As such, the use of any type of lattice cell, any density, anyangle is contemplated by this disclosure. In one exemplary embodiment,the lattice density of the left and right jaw energy attenuation members2150A,B may range between 3 to 7 pounds per cubic foot. Additionally, itshould be understood that the structural makeup and/or the chemicalcompositions of the left and right jaw energy attenuation members2150A,B may differ from: (i) all other members within the energyattenuation assembly 2000, (ii) a percentage of the members within theenergy attenuation assembly 2000, or (iii) none of the members withinthe energy attenuation assembly 2000.

Finally, a closed skin 2202 is positioned adjacent to the fitting region2026 (see FIGS. 63A-63B). The closed skin 2202 creates a substantiallysmooth surface that is designed to come into contact with the player'sforehead. The skin 2202 is integrally formed as a part of the members2150A,B and as such the lattice cells on the side of the members 2150A,Bblend into the skin 2202 as the lattice cells approach the inner surfaceof the members 2150A,B. This blending of the lattice cells into the skin2202 starts to occur prior to the shoulders 2018 of the members 2150A,B.Utilizing the skin and starting the skin 2202 in this location helpsprevent the lattice cells from imprinting their pattern on the player'shead. In one embodiment, the skin 2202 is between 0.1 mm and 5 mm;however, it should be understood that the thickness of this skin 2202may be changed. It should also be understood that the skin 2150A,B mayextend around the side regions of the members 2150A,B or may completelyencase the members 2150A,B (e.g., where the member has a substantiallysmooth surface on the outside of all sides of the members 2150A,B).

As shown in FIGS. 55A-55E and 64A-64C, the rear energy attenuationmember 2200 has a curvilinear configuration that corresponds to thecurvature of the inner surface 1017 of the helmet shell 1012. Like thefront energy attenuation member 2010, the rear energy attenuation member2200 includes: (i) means for securing or coupling 2006, such as hook andloop fasteners sold under VELCRO® or a snap connector, the members 2050to the inner shell surface 1017, (ii) indicia 2012, and (iii) trackingdevice 2014. The rear energy attenuation member 2200 includes a strutbased lattice cell that extends throughout the entire member and createsa substantially homogeneous member. This member 2200 can utilize asingle strut based lattice cell throughout the member 2200 because thecompression curve for the energy management region does not vary enoughto warrant the inclusion of an additional lattice cell type. Althoughboth the crown energy attenuation member 2050 and the rear energyattenuation member 2200 include a single strut based lattice, theselattice cell types are different and the densities of these cell typesare different. Similarly, this member 2200 does not include an exterioropen skin because, unlike a surface lattice cell, a strut based latticecell can terminate at a surface without providing a non-smooth outersurface. In one exemplary embodiment, the lattice density of the rearenergy attenuation member 2200 may range between 3 to 7 pounds per cubicfoot. It should be understood that rear energy attenuation member 2200has the same flexibility in its structural makeup and chemicalcomposition as discussed above and as such its structural makeup and/orthe chemical composition may differ from: (i) all other members withinthe energy attenuation assembly 2000, (ii) a percentage of the memberswithin the energy attenuation assembly 2000, or (iii) none of themembers within the energy attenuation assembly 2000.

As shown in FIGS. 55A-57B and 65A-65C, the occipital energy attenuationmember 2250 has a curvilinear configuration that corresponds to thecurvature of the inner surface 1017 of an extent of the rear portion ofthe shell 1012. Like the front energy attenuation member 2010, theoccipital energy attenuation member 2250 also includes: (i) means forsecuring or coupling 2006, such as hook and loop fasteners sold underVELCRO® or a snap connector, the energy attenuation member 2200 to theinner shell surface 1017, (ii) indicia 2012, and (iii) tracking device2014. Also, in this exemplary embodiment, the occipital energyattenuation member 2250 is non-homogeneous, as they includeapproximately four different layers. The first layer that is positionedadjacent to the curvature of the inner surface 1017 of the helmet shell1012 is an energy management region 2024 of the occipital energyattenuation member 2250. Overall, this energy management region 2024 isdesigned to absorb a majority of the linear and rotational energies thatare translated through the helmet shell 1012. This energy managementregion 2024 includes a strut based lattice cell. An interior open skinis positioned adjacent to the energy management region 2024 and afitting region 2026. This interior open skin may act as a dividerbetween the fitting region 2026 and the energy management region 2024,which may allow for the presence of desirable boundary conditions. Thisfitting region 2026 includes a surface based lattice cell, whichprovides desirable fitting characteristics. It should be understood thatin different embodiments or if different materials are utilized, surfacebased lattice cell types or different strut based lattice cells mayoutperform the current strut based lattice cell. As such, the use of anytype of lattice cell, any density, any angle is contemplated by thisdisclosure. In one exemplary embodiment, the lattice density of theoccipital energy attenuation member 2250 may range between 3 to 7 poundsper cubic foot. Additionally, it should be understood that thestructural makeup and/or the chemical compositions of the occipitalenergy attenuation member 2250 may differ from: (i) all other memberswithin the energy attenuation assembly 2000, (ii) a percentage of themembers within the energy attenuation assembly 2000, or (iii) none ofthe members within the energy attenuation assembly 2000.

Finally, a closed skin 2202 is positioned adjacent to the fitting region2026 (see FIG. 65A). The closed skin 2202 creates a substantially smoothsurface that is designed to come into contact with the player'sforehead. The skin 2202 is integrally formed as a part of the member2250 and as such the lattice cells on the side of the member 2250 blendinto the skin 2202 as the lattice cells approach the inner surface ofthe member 2250. This blending of the lattice cells into the skin 2202starts to occur prior to the shoulders 2018 of the member 2250.Utilizing the skin and starting the skin 2202 in this location helpsprevent the lattice cells from imprinting their pattern on the player'shead. In one embodiment, the thickness of the skin 2202 is greater than0.1 mm. It should also be understood that the skin 2202 may extendaround the side regions of the member 2250 or may completely encase themember 2250 (e.g., where the member has a substantially smooth surfaceon the outside of all sides of the member 2250).

K. Exemplary Embodiment of a Custom Energy Attenuation Assembly for Usein a Protective Contact Sports Helmet

FIGS. 67-73, 74A, 75A show an assembled stock energy attenuationassembly 3000 for use in a protective contact sports helmet, such as thefootball helmet 1000, or a hockey helmet or lacrosse helmet. The customenergy attenuation assembly 3000 is comprised of: (i) a front energyattenuation member 3010, (ii) a crown energy attenuation member 3050,(iii) left and right energy attenuation members 3100A,B, (iv) left andright jaw energy attenuation members 3150A,B, and (v) a rear combinationenergy attenuation member 3200. As shown in FIG. 72B, the custom energyattenuation assembly 3000 may include at least one badge, which may haveindicia such as a player's name, jersey number and/or signature, and/ora name, slogan or images of an entity such as a company. In particular,a player identification badge 3002, may be disposed on the rearcombination energy attenuation member 3200 while a protective sportshelmet identification badge 3004, identifying the helmet model and/ormanufacturer, may be placed on the crown energy attenuation member 3050.The identification badge 3002 may also include a reproduction of theplayer's actual signature. In addition to enhancing the aesthetic appealand desirability, the identification badge 3002 is useful in helping aplayer quickly ascertain his or her helmet from among a group ofsimilarly-appearing helmets.

The shape, structural design, and material composition of the frontenergy attenuation member 3010, the crown energy attenuation member3050, the left and right energy attenuation members 3100A,B, the leftand right jaw energy attenuation members 3150A,B, and the rearcombination energy attenuation member 3200, are discussed in greaterdetail below. However, it should at least be understood that each membercontained within the energy attenuation assembly 3000 may have differentimpact responses when compared to other members within the energyattenuation assembly 3000. In fact, even different regions within thesame member may have different impact responses when compared to oneanother. These differing impact responses may be utilized by thedesigner to adjust how the energy attenuation assembly 3000 and in turnthe helmet 1000 responds to impact forces. As discussed in greaterdetail below, these differing impact responses may be obtained byvarying the structural makeup and/or the chemical composition of theenergy attenuation assembly 3000.

While additional details will be provided below, the exemplaryembodiment of the stock energy attenuation assembly 3000 contains atleast nine different member regions. The member regions are splitamongst the energy attenuation assembly 3000, as follows: (i) tworegions within the front energy attenuation member 3010, (ii) one regionwithin the crown energy attenuation member 3050, (iii) two regionswithin the left and right energy attenuation members 3100A,B, (iv) tworegions within the left and right jaw energy attenuation members3150A,B, and (v) two regions within the rear combination energyattenuation member 3200. The exemplary embodiment of the custom energyattenuation assembly 3000 also includes at least six different strutbased lattice cell types. For example, the front energy attenuationmember 3010 lattice cell type is different than the lattice cell typethat is contained within the crown energy attenuation member 3050.Further, the exemplary embodiment of the custom energy attenuationassembly 3000 includes multiple different lattice densities. Thesedifferences can be seen by visually comparing the crown energyattenuation member 3050 with the rear energy attenuation member 3200. Itshould be understood that in different embodiments, the energyattenuation assembly 3000 may have different number of member regions,types of lattice cells, and lattice density values. For example, theenergy attenuation assembly 3000 may have between: (i) 1 and X differentlattice cell types, where X is the number of lattice cells containedwithin the assembly 3000, (ii) 1 and Y different lattice memberthicknesses, where Y is the number of lattice cells contained within theassembly 3000, (iii) 1 and Z different lattice densities, where Z is thenumber of lattice cells contained within the assembly 3000, and (iv) 1and U different member regions, where U is the number of lattice cellscontained within the assembly 3000. In one exemplary embodiment, thelattice density of the front energy attenuation member may range between3 to 17 pounds per cubic foot and preferably between 4 to 9 pounds percubic foot.

As shown in FIGS. 67-68C, the front energy attenuation member 3010 has acurvilinear configuration that corresponds to the curvature of the innersurface 1017 of the shell 1012 and the cantilevered segment 1044. Thefront energy attenuation member 3010 also has: (i) a recessed centralregion 3421 that facilitates engagement of the crown energy attenuationmember 3050 and (ii) peripheral recesses 3422 that facilitatesengagement of the energy attenuation member 3010 with the left and rightenergy attenuation members 3100A,B. When the helmet 1000 is worn by theplayer, the front energy attenuation member 3010 engages the player'sfrontal bone or forehead while extending laterally between the player'stemple regions and extending vertically from the player's brow lineacross the player's forehead. The front energy attenuation member 3010also includes means 3006 for securing or coupling, such as hook and loopfasteners sold under VELCRO® or a snap connector, the energy attenuationmember 3010 to the inner shell surface 1017. As shown in FIG. 68A, thefront energy attenuation member 3010 also includes a surface or panelthat allows for indicia 3012, such as the manufacturer of the helmet1000, a team name, a player's name, and/or the month and year the memberwas manufactured. Further, the front energy attenuation member 3010includes a surface or panel that allows for tracking device 3014, suchas a bar code or QR code. In other embodiments, the tracking device 3014may be RFID chips or other electronic chips that can be scanned from theexterior of the helmet and used for tracking purposes.

The front energy attenuation member 3010 includes two different regions,a fitting region 3024 and an energy management region 2026. Both ofthese regions 3024, 3026 include strut based lattices; however, thesestrut based lattices are different from one another. From the abovedisclosure, it should be understood that both the structural makeup(e.g., lattice cell types, geometry of each lattice cell type, latticedensities, lattice angles) and the chemical compositions may varydepending on whether the front energy attenuation member 3010 isdesigned for: (i) a group of all players, (ii) a specific position(e.g., lineman), (iii) a specific playing level (e.g., NCAA players), or(iv) a position and playing level design (e.g., varsity quarterback).For example, FIG. 40 shows different possible designs for the frontenergy attenuation member 3010, where one design may be for a youthlineman, while another is designed for a varsity cornerback.

As shown in FIGS. 67-73, that each member 3010, 3050, 3100, 3150, 3200has an exterior closed skin 3202 that creates a substantially smoothsurface. The lattice cells on the sides of the member 3200 blends intothe skin 3202 as the lattice cells approach the inner surface of themember 3010, 3050, 3100, 3150, 3200. This skin 3202 creates asubstantially smooth surface that helps prevent the lattice cells fromimprinting their pattern on the player's head. Also, this skin 3202 doesnot hinder the compression of the lattice cells when a force is appliedto the member 3200. In one embodiment, the skin 3202 may have athickness that is greater than 0.1 mm; however, it should be understoodthat the thickness of this skin 3202 may be changed. Further, like othercomponents of the member, the thickness of this skin 3202 may alter themechanical characteristics (e.g., impact absorption) of the member 3200.It should be understood that in some embodiments the skin 3202 may beexternal to the member 3200 and/or removable. It should also beunderstood that the skin 3202 may extend around the side regions of themember 3200 or may completely encase the member 3200 (e.g., where themember has a substantially smooth surface on the outside of all sides ofthe member 3010, 3050, 3100, 3150, 3200, while the lattice cells arepositioned within the skin 3202).

As shown in FIGS. 67 and 70A-70B, the left and right energy attenuationmembers 3100A,B have a curvilinear configuration that corresponds to thecurvature of the inner surface 1017 of an extent of the side shellportions 1024. The left and right energy attenuation members 3100A,Balso have: (i) first peripheral recesses 3424 that facilitate engagementof the energy attenuation members 3100A,B with the front energyattenuation member 3010, (ii) second peripheral recesses 3426 thatfacilitate engagement of the energy attenuation members 3100A,B with theleft and right jaw energy attenuation members 3150A,B, and (iii) thirdperipheral recesses 3428 that facilitate engagement of the energyattenuation members 3100A,B with the rear combination energy attenuationmember 3200. Like the front energy attenuation member 3010, the left andright energy attenuation members 3100A,B also include: (i) means forsecuring or coupling 3006, such as hook and loop fasteners sold underVELCRO® or a snap connector, the members 3150A,B to the inner shellsurface 1017, (ii) indicia 3012, and (iii) tracking device 3014.

The left and right energy attenuation members 3100A,B includes twodifferent regions, a fitting region 3026 and an energy management region3024. Both of these regions 3024, 3026 include strut based lattices;however, these strut based lattices are different from one another.Also, the left and right energy attenuation members 3100A,B have thesame flexibility in their structural makeup and chemical composition asdiscussed above in connection with FIGS. 68A-68C and the front energyattenuation member 3010. In other words, the combinations of structuralmakeups and chemical compositions discussed in connection with frontenergy attenuation member 3010 apply with equal force to the left andright energy attenuation members 3100A,B. In one exemplary embodiment,the lattice density of the left and right energy attenuation members3100A,B may range between 3 to 7 pounds per cubic foot. It should beunderstood that the structural makeup and/or the chemical compositionsof the left and right energy attenuation members 3100A,B may differfrom: (i) all other members within the energy attenuation assembly 3000,(ii) a percentage of the members within the energy attenuation assembly3000, or (iii) none of the members within the energy attenuationassembly 3000. In one embodiment, the left and right energy attenuationmembers 3100A,B may have a denser lattice than the crown energyattenuation member 3050.

As shown in FIGS. 67 and 71A-71D, the left and right jaw energyattenuation members 3150A,B have a curvilinear configuration thatcorresponds to the curvature of the inner surface 1017 of an extent ofthe ear flap 1026 portions of the shell 1012. The left and right jawenergy attenuation members 3150A,B are configured to engage with theleft and right energy attenuation members 3100A,B. Like the front energyattenuation member 3010, the left and right jaw energy attenuationmembers 3150A,B also includes: (i) means for securing or coupling 3006,such as hook and loop fasteners sold under VELCRO® or a snap connector,the energy attenuation members 3150A,B to the inner shell surface 1017,(ii) indicia 3012, and (iii) tracking device 3014. The left and rightjaw energy attenuation members 3150A,B includes two different regions, afitting region 3026 and an energy management region 3024. Both of theseregions include strut based lattices; however, these strut basedlattices are different from one another. Like the front energyattenuation member 3010, the left and right jaw energy attenuationmembers 3150A,B have the same flexibility in their structural makeup andchemical composition as discussed above in connection with the frontenergy attenuation member 3010. In other words, the combinations ofstructural makeups and chemical compositions discussed in connectionwith the front energy attenuation member 3010 apply with equal force tothe left and right jaw energy attenuation members 3150A,B. In oneexemplary embodiment, the lattice density of the left and right jawenergy attenuation members 3150A,B may range between 3 to 7 pounds percubic foot. It should be understood that the structural makeup and/orthe chemical compositions of the left/right members may differ from: (i)all other members within the energy attenuation assembly 3000, (ii) apercentage of the members within the energy attenuation assembly 3000,or (iii) none of the members within the energy attenuation assembly3000. In one embodiment, the left and right jaw energy attenuationmembers 3150A,B may have a less lattice than the front energyattenuation member 3010.

As shown in FIGS. 67 and 72A-73, the rear combination energy attenuationmember 3200 has a curvilinear configuration that corresponds to thecurvature of the inner surface 1017 of the extent of the rear portion ofthe shell 1012. The rear combination energy attenuation member 3200 isconfigured to engage with the left and right energy attenuation members3100A,B and the crown energy attenuation member 3050. Like the frontenergy attenuation member 3010, the rear combination energy attenuationmember 3200 also includes: (i) means for securing or coupling 3006, suchas hook and loop fasteners sold under VELCRO® or a snap connector, theenergy attenuation member 3200 to the inner shell surface 1017, (ii)indicia 3012, and (iii) tracking device 3014. Like the front energyattenuation member 3010, the rear combination energy attenuation member3200 has the same flexibility in their structural makeup and chemicalcomposition as discussed above in connection with the front energyattenuation member 3010.

This combination member 3200 could not practically be done using themolding process that is described in U.S. patent application Ser. No.15/655,490 because the mechanical properties (e.g., absorption of aforce) of the members could not be altered enough to optimize how themembers, in combination with the shell 1012, reacted to an impact force.However, additive manufacturing techniques allow for the creation of amember that has regions with vastly different mechanical properties(e.g., absorption of a force). For example, the combination member 3200may be comprised of: (i) consistent composition of one type ofpolyurethane and a second type of polyurethane, (ii) a first region3210, which has a first lattice cell type and a first density, (iii) asecond region 3212, which has a first lattice cell type and a seconddensity, (iv) a third region 3214, which has a second lattice cell typeand a third density, and (v) a 3216 fourth region, which has a thirdlattice cell type and a fourth density. Even though the chemicalcomposition of this combination member 3200 is substantially uniform,the mechanical properties of each region (e.g., first, second, third,and fourth regions) differ due in part to the differing latticevariables that are contained within each region. For example, acompression force will fully compress or bottom out the first regionbefore the third or fourth regions bottom out. Likewise, a compressionforce will fully compress or bottom out the fourth region before thethird region bottoms out.

Another embodiment of the rear combination member 3300 is disclosed inFIGS. 74A-75C. In particular, this embodiment of the rear combinationmember 3300 includes two regions, wherein the first region is 3310 andthe second region is 3320. The first region 3310 is comprised of afitting region 3026. The compressions information associated with thisregion is shown in FIGS. 74B-74C, which provides the percent the member3010 is compressed is shown on the X-axis and the pressure (psi) ittakes to compress the member 3010 to that extent is shown on the Y-Axis.The second region 3320 is comprised of an energy management region 3024.The compressions information associated with this region is shown inFIGS. 75B-74C, which provides the percent the member 3010 is compressedis shown on the X-axis and the pressure (psi) it takes to compress themember 3010 to that extent is shown on the Y-Axis. Comparing the firstregion 3310 to the second region 3320, it can be seen that at an 80%compression level the first region requires approximately 40 psi and thesecond region requires approximately 200 psi. This is about a five timesdifference between these regions. Additional information about thecompression of these regions is disclosed within the graphs containedherein.

L. Industrial Application

In addition to applying to protective contact sports helmets—namely,football, hockey and lacrosse helmets—the disclosure contained hereinmay be applied to design and develop helmets for: baseball player,cyclist, polo player, equestrian rider, rock climber, auto racer,motorcycle rider, motocross racer, skier, skater, ice skater,snowboarder, snow skier and other snow or water athletes, skydiver. Themethod, system, and devices described herein may be applicable to otherbody parts (e.g., shins, knees, hips, chest, shoulders, elbows, feet andwrists) and corresponding gear or clothing (e.g., shoes, shoulder pads,elbow pads, wrist pads).

As is known in the data processing and communications arts, ageneral-purpose computer typically comprises a central processor orother processing device, an internal communication bus, various types ofmemory or storage media (RAM, ROM, EEPROM, cache memory, disk drivesetc.) for code and data storage, and one or more network interface cardsor ports for communication purposes. The software functionalitiesinvolve programming, including executable code as well as associatedstored data. The software code is executable by the general-purposecomputer. In operation, the code is stored within the general-purposecomputer platform. At other times, however, the software may be storedat other locations and/or transported for loading into the appropriategeneral-purpose computer system.

A server, for example, includes a data communication interface forpacket data communication. The server also includes a central processingunit (CPU), in the form of one or more processors, for executing programinstructions. The server platform typically includes an internalcommunication bus, program storage and data storage for various datafiles to be processed and/or communicated by the server, although theserver often receives programming and data via network communications.The hardware elements, operating systems and programming languages ofsuch servers are conventional in nature, and it is presumed that thoseskilled in the art are adequately familiar therewith. The serverfunctions may be implemented in a distributed fashion on a number ofsimilar platforms, to distribute the processing load.

Hence, aspects of the disclosed methods and systems outlined above maybe embodied in programming. Program aspects of the technology may bethought of as “products” or “articles of manufacture” typically in theform of executable code and/or associated data that is carried on orembodied in a type of machine-readable medium. “Storage” type mediaincludes any or all of the tangible memory of the computers, processorsor the like, or associated modules thereof, such as varioussemiconductor memories, tape drives, disk drives and the like, which mayprovide non-transitory storage at any time for the software programming.All or portions of the software may at times be communicated through theInternet or various other telecommunication networks. Thus, another typeof media that may bear the software elements includes optical,electrical and electromagnetic waves, such as used across physicalinterfaces between local devices, through wired and optical landlinenetworks and over various air-links. The physical elements that carrysuch waves, such as wired or wireless links, optical links or the like,also may be considered as media bearing the software. As used herein,unless restricted to non-transitory, tangible “storage” media, termssuch as computer or machine “readable medium” refer to any medium thatparticipates in providing instructions to a processor for execution.

A machine-readable medium may take many forms, including but not limitedto, a tangible storage medium, a carrier wave medium or physicaltransmission medium. Non-volatile storage media include, for example,optical or magnetic disks, such as any of the storage devices in anycomputer(s) or the like, such as may be used to implement the disclosedmethods and systems. Volatile storage media include dynamic memory, suchas main memory of such a computer platform. Tangible transmission mediainclude coaxial cables, copper wire and fiber optics, including thewires that comprise a bus within a computer system. Carrier-wavetransmission media can take the form of electric or electromagneticsignals, or acoustic or light waves such as those generated during radiofrequency (RF) and infrared (IR) data communications. Common forms ofcomputer-readable media therefore include for example: a floppy disk, aflexible disk, hard disk, magnetic tape, any other magnetic medium, aCD-ROM, DVD or DVD-ROM, any other optical medium, punch cards, papertape, any other physical storage medium with patterns of holes, a RAM, aPROM and EPROM, a FLASH-EPROM, any other memory chip or cartridge, acarrier wave transporting data or instructions, cables or linkstransporting such a carrier wave, or any other medium from which acomputer can read programming code and/or data. Many of these forms ofcomputer readable media may be involved in carrying one or moresequences of one or more instructions to a processor for execution.

It is to be understood that the invention is not limited to the exactdetails of construction, operation, exact materials or embodiments shownand described, as obvious modifications and equivalents will be apparentto one skilled in the art. While the specific embodiments have beenillustrated and described, numerous modifications come to mind withoutsignificantly departing from the spirit of the invention, and the scopeof protection is only limited by the scope of the accompanying Claims.

What is claimed is:
 1. A football helmet comprising: a shell configuredto receive a head of a wearer of the football helmet, the shellincluding: a crown portion defining an upper region of the shell; afront portion extending generally forwardly and downwardly from thecrown portion; a rear portion extending generally rearwardly anddownwardly from the crown portion; and left and right side portionsextending generally laterally and downwardly from the crown portion; andan energy attenuation assembly removably positioned within the shell,wherein a first energy attenuation member of the energy attenuationassembly has both an energy management region and a fitting region,wherein: (A) the energy management region includes a plurality oflattice cells that are a first lattice cell type and are manufacturedusing an additive manufacturing process, and wherein the energymanagement region: (i) is positioned between the shell and the fittingregion, (ii) is configured to absorb a majority of energy transmittedthrough the shell from an impact to the shell and (iii) has differentenergy absorption properties than energy absorption properties of thefitting region; and (B) the fitting region includes a plurality oflattice cells that are a second lattice cell type that is different fromthe first lattice cell type, and wherein the fitting region ispositioned between the energy management region and the wearer's headwhen the helmet is worn by the wearer; and wherein compression of theenergy attenuation assembly exerts a pre-impact pressure of 1 to 10pounds per square inch on the wearer's head when the helmet is worn bythe wearer.
 2. The football helmet of claim 1, wherein the fittingregion of the first energy attenuation member is formed using saidadditive manufacturing process.
 3. The football helmet of claim 1,wherein the first energy attenuation member has an original thickness inan uncompressed state occurring when the helmet is not being worn by thewearer, and wherein when the helmet is worn by the wearer, the originalthickness is reduced by 1% to 15% due to compression of an extent of thefitting region.
 4. The football helmet of claim 1, wherein the firstenergy attenuation member includes: (i) at least three different latticecells and (ii) two different lattice densities.
 5. The football helmetof claim 1, wherein the first energy attenuation member furtherincludes: (i) an exterior closed skin that is substantially smooth andconfigured to be positioned between the fitting region and the wearer'shead when the helmet is worn by the wearer and (ii) an interior openskin that has openings formed there through, is positioned between thefitting region and the energy management region, and is integrallyformed with both the fitting region and the energy management region. 6.The football helmet of claim 1, wherein the first energy attenuationmember further includes an exterior open skin that (i) is integrallyformed with the energy management region and (ii) is positioned betweenthe energy management region and an inner surface of the shell.
 7. Thefootball helmet of claim 1, wherein the first lattice cell type is asurface-based lattice cell type and the second lattice cell type is astrut-based lattice cell type.
 8. The football helmet of claim 1,wherein the first lattice cell type is a first strut-based lattice celltype and the second lattice cell type is a second strut-based latticecell type that is different than the first lattice cell type.
 9. Thefootball helmet of claim 1, wherein the energy attenuation assemblyincludes a second energy attenuation member, wherein the first energyattenuation member is made from a first material and the second energyattenuation member is made from a second material, wherein the firstmaterial is different from the second material.
 10. The football helmetof claim 1, wherein the energy attenuation assembly includes a secondenergy attenuation member that is positioned inward and adjacent to oneof the left and right side portions of the shell, wherein: (i) the firstenergy attenuation member has an original thickness in an uncompressedstate, and wherein compressing the first energy attenuation member to25% of its original thickness requires a first force; (ii) the secondenergy attenuation member has an original thickness in the uncompressedstate, and wherein compressing the second energy attenuation member to25% of its original thickness requires a second force; and wherein thesecond force is less than the first force.
 11. The football helmet ofclaim 1, wherein the energy attenuation assembly includes a secondenergy attenuation member, wherein the first energy attenuation memberhas a first overall density that is between 3 and 17 pounds per cubicfoot and the second energy attenuation member has a second overalldensity that is between 3 and 7 pounds per cubic foot.
 12. A footballhelmet comprising: a shell configured to receive a head of a wearer ofthe football helmet, the shell including: a crown portion defining anupper region of the shell; a front portion extending generally forwardlyand downwardly from the crown portion; a rear portion extendinggenerally rearwardly and downwardly from the crown portion; and a pairof side portions extending generally laterally and downwardly fromopposed sides of the crown portion; and an energy attenuation assemblypositioned within the shell, the energy attenuation assembly including:(A) a front energy attenuation member that is positioned adjacent thefront portion of the shell, wherein the front energy attenuation member:(i) is manufactured using an additive manufacturing process with aplurality of lattice cells that include a first lattice cell type, (ii)has an original thickness of the front energy attenuation member in anuncompressed state, and (iii) requires a first force to compress thefront energy attenuation member to 80% of the original thickness; (B) aside energy attenuation member that is positioned adjacent one of theside portions of the shell, wherein the side energy attenuation member:(i) is manufactured using the additive manufacturing process with aplurality of lattice cells that include a second lattice cell type thatdiffers from the first lattice cell type of the front energy attenuationmember, (ii) has an original thickness of the side energy attenuationmember in an uncompressed state, and (iii) requires a second force tocompress the side energy attenuation member to 80% of the originalthickness; and wherein the first force is at least 10% greater than thesecond force.
 13. The football helmet of claim 12, wherein the pluralityof lattice cells within the front energy attenuation member furtherincludes a second lattice cell type; wherein when the helmet is worn bythe wearer, (i) the second lattice cell type is positioned between thefirst lattice cell type and the wearer's head; and (ii) the firstlattice cell type is positioned between the shell and the second latticecell type.
 14. The football helmet of claim 13, wherein the firstlattice cell type is a surface-based lattice cell type and the secondlattice cell type is a strut-based lattice cell type.
 15. The footballhelmet of claim 12, wherein the second lattice cell type within the sideenergy attenuation is a strut-based lattice cell type.
 16. The footballhelmet of claim 12, wherein the energy attenuation assembly furthercomprising a crown energy attenuation member, wherein the crown energyattenuation member includes at least a strut-based lattice cell type.17. The football helmet of claim 12, wherein the energy attenuationassembly exerts a pre-impact pressure of 1 to 10 pounds per square inchon the wearer's head when the helmet is worn by the wearer.
 18. Thefootball helmet of claim 12, wherein the plurality of lattice cellswithin the front energy attenuation member further includes a secondlattice cell type; and wherein when the helmet is worn by the wearer,the original thickness of the front energy attenuation member is reducedby 1% to 15% due to compression of an extent of the plurality of latticecells having the second lattice cell type.
 19. The football helmet ofclaim 12, wherein the front energy attenuation member includes asubstantially smooth exterior closed skin that is configured to bepositioned adjacent to the wearer's head when the helmet is worn by thewearer, and wherein the exterior closed skin has a thickness that isgreater than 0.1 mm.
 20. The football helmet of claim 12, wherein theenergy attenuation assembly includes a rear energy attenuation memberthat is positioned inward and adjacent the rear portion of the helmet,wherein the rear energy attenuation member: (a) is manufactured usingthe additive manufacturing process with a plurality of lattice cells,(b) includes a first region that is configured to be positioned adjacentto the wearer's head when the helmet is worn by the wearer, and (c)includes a second region that is configured to be positioned adjacent tothe shell.
 21. The football helmet of claim 20, wherein: (a) the firstregion of the rear energy attenuation member has a first lattice densityand an original thickness in an uncompressed state occurring when thehelmet is not being worn by the wearer, and wherein compressing thefirst region of the rear energy attenuation member to 25% of itsoriginal thickness requires a first rear force; (b) the second region ofthe rear energy attenuation member has a second lattice density and anoriginal thickness in the uncompressed state, and wherein compressingthe second region of the rear energy attenuation member to 25% of itsoriginal thickness requires a second rear force; and wherein the firstlattice density is different than the second lattice density and thesecond rear force is at least 50% greater than the first rear force. 22.A football helmet comprising: a shell configured to receive a head of awearer of the football helmet, the shell including: a crown portiondefining an upper region of the shell; a front portion extendinggenerally forwardly and downwardly from the crown portion; a rearportion extending generally rearwardly and downwardly from the crownportion; and left and right side portions extending generally laterallyand downwardly from the crown portion; and an energy attenuationassembly positioned within the shell, the energy attenuation assemblyincluding a front energy attenuation member that is positioned adjacentthe front portion of the shell, wherein the front energy attenuationmember: (i) is manufactured from a polyurethane material using anadditive manufacturing process, (ii) includes a first region that has afirst lattice cell with a first lattice type, and (iii) includes asecond region that is integrally formed with the first region and has asecond lattice cell with a second lattice type that is structurallydifferent from the first lattice type.
 23. The football helmet of claim22, wherein the front energy attenuation member further includes asubstantially smooth exterior closed skin that is integrally formed withthe second region of the front energy attenuation member.
 24. Thefootball helmet of claim 23, wherein an inner surface of thesubstantially smooth exterior closed skin has a topography that isconfigured to substantially match a surface that is derived from a scanof the wearer's head.
 25. The football helmet of claim 22, wherein thesecond lattice type is a strut-based lattice type and the first latticetype is a surface-based lattice type.
 26. The football helmet of claim22, wherein the front energy attenuation member has an originalthickness in an uncompressed state occurring when the helmet is notbeing worn by the wearer; and wherein when the helmet is worn by thewearer and the helmet receives an impact that causes the originalthickness to be reduced by at least 16%, said impact will compress thesecond region and an extent of the first region.
 27. The football helmetof claim 22, wherein the energy attenuation assembly exerts a pre-impactpressure of 1 to 10 pounds per square inch on the wearer's head when thehelmet is worn by the wearer.
 28. The football helmet of claim 22,wherein the first region is an energy management region positionedbetween the shell and the second region and the second region is afitting region positioned between the energy management region and thewearer's head when the helmet is worn by the wearer.
 29. The footballhelmet of claim 28, wherein the energy management region has differentenergy absorption properties than energy absorption properties of thefitting region and is configured to absorb a majority of energytransmitted through the shell from an impact to the shell.
 30. Thefootball helmet of claim 22, wherein the front energy attenuation memberhas an original thickness in an uncompressed state occurring when thehelmet is not being worn by the wearer, and wherein when the helmet isworn by the wearer, the original thickness is reduced by 1% to 15% dueto compression of an extent of the second region.
 31. The footballhelmet of claim 22, wherein the energy attenuation assembly includes aside energy attenuation member that is positioned inward and adjacent toone of the left and right side portions of the shell, wherein: (i) thefront energy attenuation member has an original thickness in anuncompressed state, and wherein compressing the first energy attenuationmember to 25% of its original thickness requires a first force; (ii) theside energy attenuation member has an original thickness in theuncompressed state, and wherein compressing the second energyattenuation member to 25% of its original thickness requires a secondforce; and wherein the second force is less than the first force. 32.The football helmet of claim 22, wherein the energy attenuation assemblyincludes a side energy attenuation member positioned inward and adjacentto one of the left and right side portions of the shell, wherein: (i)the front energy attenuation member has an original thickness in anuncompressed state, and wherein compressing the first energy attenuationmember to 80% of its original thickness requires a first force; (ii) theside energy attenuation member is manufactured using an additivemanufacturing process and has an original thickness in the uncompressedstate, and wherein compressing the second energy attenuation member to80% of its original thickness requires a second force; and wherein thesecond force is less than the first force; and wherein the first forceis at least 10% greater than the second force.
 33. The football helmetof claim 22, wherein the energy attenuation assembly includes a rearenergy attenuation member that is positioned inward and adjacent therear portion of the helmet, wherein the rear energy attenuation member:(a) is manufactured using the additive manufacturing process with aplurality of lattice cells, (b) includes a first region that isconfigured to be positioned adjacent to the wearer's head when thehelmet is worn by the wearer, and (c) includes a second region that isconfigured to be positioned adjacent to the shell.
 34. The footballhelmet of claim 33, wherein: (a) the first region of the rear energyattenuation member has a first lattice density and an original thicknessin an uncompressed state occurring when the helmet is not being worn bythe wearer, and wherein compressing the first region of the rear energyattenuation member to 25% of its original thickness requires a firstrear force; (b) the second region of the rear energy attenuation memberhas a second lattice density and an original thickness in theuncompressed state, and wherein compressing the second region of therear energy attenuation member to 25% of its original thickness requiresa second rear force; and wherein the first lattice density is differentthan the second lattice density and the second rear force is at least50% greater than the first rear force.